ARMY TECHNICAL MANUAL TM5-6115-585-3 4

NAVY PUBLICATION NAVFACP-8-262-1 2

AIR FORCE TECHNICAL ORDER TO-35C2-3-455- 2

MARINE CORPS TECHNICAL MANUAL TM-05684C-3 4

TECHNICAL MANUA L

INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT )

AND DEPOT LEVEL MAINTENANCE MANUA L

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW, 1 PHASE

-2 WIRE, 1 PHASE -3 WIRE,3PHASE -4 WIRE, 120, 120/240 AND 120/208 VOLTS

DOD MODEL CLASS HERTZ NSN

MEP-003A UTILIT Y 60 6115-00-465-1030

This copy is a reprint which includes curren t

pages from Changes 1 through 9 .

PUBLISHED UNDER THE AUTHORITY OF THE DEPARTMENTS OF THE ARMY,

AIR FORCE, NAVY, AND HEADQUARTERS U.S. MARINE CORPS

JULY 1977
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

WARNING

All specific cautions

adhered to. Otherwise,

result.

and warnings contained in this manual shall be strictly

severe injury, death and/or damage to the equipment may

HIGH VOLTAGE

is produced when this Generator Set is in operation.

DEATH

or severe burns may result if personnel fail to observe safety precautions. Do not

operate this Generator Set until the ground terminal stud has been connected to a

suitable ground. Disconnect the battery ground cable before removing and installing

components on the engine or in the electrical control panel system. Remove all

rings, watches, and other jewelry when performing maintenance on this equipment.

Loose fitting clothing should be secured to prevent it catching in moving parts. DO

not attempt to service or otherwise make any adjustments, connections or reconnection of wires or cables until Generator Set is shut-down and completely deenergized.

DANGEROUS GASES

Batteries generate explosive gas during charging: therefore, utilize extreme

caution, do not smoke, or use open flame in the vicinity of the Generator Set when

servicing batteries.

Exhaust discharge contains noxious and deadly fumes. Do not operate Generator

Sets in enclosed areas unless exhaust discharge is properly vented to the outside.

To avoid sparking between filler nozzle and fuel tank, always maintain metal to

metal contact between filler nozzle and fuel tank when filling fuel tank.

Do not smoke or use open flame in the vicinity of the Generator Set while fueling.

LIQUIDS UNDER HIGH PRESSURE

are generated as a result of operation of the Generator Set. Do not expose any

part of the body to a high pressure leak in the fuel injection system.

WARNING

Clean parts in a well-ventilated area. Avoid inhalation of solvent fumes and prolonged exposure of skin to cleaning solvent. Wash exposed skin thoroughly. Dry

cleaning solvent (Fed. Spec. P-D-680) used to clean parts is potentially dangerous

to personnel and property. Do not use near open flame or excessive heat. Flash

point of solvent is 100° F. to 138° F. (38° C. to 59° C.).

WARNING

If conditions require fuel tank repairs by welding or other methods involving heat

or flame, take care to assure that all fumes are purged from the tank or fill tank

with water before commencing the repair. If possible, tank should be filled with

water prior to welding after being thoroughly purged of fumes. Applying heat or

flame to a fuel tank containing residue, may result in a violent explosion, causing

death or injury to maintenance personnel.

NOISE

Operating level of this generator can cause hearing damage.

recommended by the medical or safety officer, must be worn

this set.

Ear protectors, as

when working near
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

C 9

CHANGE HEADQUARTERS,

DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE

AND HEADQUARTERS U.S. MARINE CORPS

NO. 9 WASHINGTON, D. C., 4 MAY 1992

Intcrmediate (Field) (Direct and General Support)

and Depot Level Maintenance Manual

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD

10 KW, 1 PHASE-2 WIRE, 1 PHASE-3 WIRE, 3 PHASE-4 WIRE

120, 120/240 AND 120/208 VOLTS

DOD MODEL CLASS HERTZ NSN

MEP-003A UTILITY 60 6115-00-465-1030

MEP-112A UTILITY 400 6115-00-465-1027

Approved for public release; distribution is unlimited

TM 5-6115–585–34/NAVFACP-8–623–34n0-35 C2-3-455-2/TM-05684C/05685B-34, 25 July 1977, is

changed as follows:

1. Remove and insert pages as indicated below. Page 1–10.1/(1–10.2 blank) was changed in Change 7;

however, the Change transmittal sheet inadvertently omitted instructions to remove the original page

1–10.1/(1-10.2 blank) before inserting the change page. The Change 7 page 1–10.1/(1–10.2 blank) also did not

include any change indicators or number. To eliminate any confusion, therefore, as to which page should be used,

the most current page is included in Change 9; the change indicated by the miniature pointing hand was included in

Change 7, but was not indicated by a pointing hand.

Remove pages Insert pages

1–10.1/(1–10.2 blank) 1-10.1/(1–10.20 blank)

2. Retain this sheet in front of manual for reference purposes.
Milton H. Hamilton

TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685 B-34

C9

By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps):

GORDON R. SULLIVAN

Official:

MILTON H. HAMILTON

Administrative Assistant to the

Secretary ot the Army

01110

Official:

CHARLES C. McDONALD

General, USAF

Commander, Air Force Logistics Command

General, United States Army

Chief of Staff

MERRILL A. McPEAK

General USAF

Chief of Staff

DAVID E. BOTTORFF

Rear Admiral, CEC, US Navy

Commander

Navy Facilities Engineering Command

H.E. REESE

Deputy for Support

Marine Corps Research, Development and

Acquisition Command

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0870
















DEPARTMENT OF THE ARMY TECHNICAL MANUAL TM5-6115-585-34

DEPARTMENT OF THE NAVY PUBLICATION NAVFAC P-8-623-34

DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER TO-35C2-3-455-2

MARINE CORPS TECHNICAL MANUAL TM-05684C/05685B-34

HEADQUARTERS

DEPARTMENTS OF THE ARMY, NAVY, AIR FORCE, & USMC

WASHINGTON, D.C. 25 JULY 1977

INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)

AND DEPOT LEVEL MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD 10KW,

-2 WIRE, 1 PHASE - 3 WIRE, 3 PHASE - 4 WIRE, 120, 120/240 AND 120/208

DOD MODEL CLASS HERTZ NSN

MEP-003A UTILITY 60 6115-00-465-1030

MEP-112A UTILITY 400 6115-00-465-1027

1 PHASE

VOLTS

TABLE OF CONTENTS

CHAPTER 1.

Section I.

Section II.

CHAPTER 2.

Section I.

Section II.

LIST OF EFFECTIVE PAGES. . . . . . . . . . . . . . . . . . . . .

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . .

LIST OF TABLES..... . . . . . . . . . . . . . . . . .

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Limited Applicability . . . . . . . . . . . . . . . . . . . . .

1-3. Maintenance Forms and Records . . . . . . . . . . . . . . .

1-4. Reporting of Errors . . . . . . . . . . . . . . . . . . . . . .

1-5. Levels of Maintenance Accomplishment . . . . . . . . . . .

DESCRIPTION AND TABULATED DATA . . . . . . . . . . . . . . .

1-6. Description. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . .

REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND

DIAGNOSIC EQUIPMENT (TMD E), AND SUPPORT EQUIPMENT .

2-1. Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Tools and Equipment . . . . . . . . . . . . . . . . . . . . . .

2-3. Fabricated Tools and Equipment . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Malfunctions Not Corrected By Use of the Troubleshooting

Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

iv

v

 vi

1-1

1-1

1-1

1-1

1-1

1-1

1-1

1-1

1-1

1-1

2-1

2-1

2-1

2-1

2-1

2-5

2-5

2-5

Change 2 i
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C/05685B-34

TABLE OF CONTENTS (CONT)

Section III.

Section IV.

CHAPTER 3.

Section I.

Section II .

CHAPTER 4.

Section I.

Section II .

CHAPTER 5.

Section I.

Section II .

CHAPTER 6.

Section I.

Section II.

GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .

2-6. General Maintenance . . . . . . . . . . . . . . . . . . . . . .

2-7. General Maintenance Procedures . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION OF MAJOR COMPONENTS . . . .

2-8. Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Generator Assembly . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF COOLING SYSTEM . . . . . . . . . . . . . . .

DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . .

3-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Engine Cooling System . . . . . . . . . . . . . . . . . . . .

3-3. High Temperature Cut Out Switch . . . . . . . . . . . . . .

MAINTENANCE OF FUEL SYSTEM . . . . . . . . . . . . . . . . .

DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . .

4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF FUEL TANK. . . . . . . . . . . . . . . . . . .

4-2. Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF STARTING SYSTEM . . . . . . . . . . . . . . .

DESCRIPTION AND FUNCTION.. . . . . . . . . . . . . . . . . . .

5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF CONTROL SYSTEM . . . . . . . . . . . . . . .

DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . .

6-1. DC Control System . . . . . . . . . . . . . . . . . . . . . . .

6-2. AC Instrumentation System . . . . . . . . . . . . . . . . . .

6-3. Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Generator Set Wiring Harness . . . . . . . . . . . . . . . .

6-6. Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . .

6-7. AC Output Control Box Wiring Harness . . . . . . . . . . . .

6-8. AC Output Control Box Assembly . . . . . . . . . . . . . . .

6-9. AC Output Control Box (Internal Components) . . . . . . . .

Page

2-12

2-12

2-12

2-12

2-12

2-12

2-16

3-1

3-1

3-1

3-1

3-1

3-1

4-1

4-1

4-1

4-1

4-1

5-1

5-1

5-1

5-1

5-1

6-1

6-1

6-1

6-1

6-1

6-1

6-1

6-8

6-8

6-9

6-9

6-9

i i
CHAPTER 7.

Section I.

Section II.

Section III.

CHAPTER 8.

Section I.

Section II

CHAPTER 9.

Section I.

Section II.

Section III.

TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

TABLE OF CONTENTS (CONT)

MAINTENANCE OF ENGINE. . . . . . . . . . . . . . . . . . . . .

DESCRIPTION AND FUNCTION. . . . . . . . . . . . . . . . . . . .

7-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE EXTERNAL ASSEMBLY.. . . . . . . . . . . . . . . . . .

7-2. Fuel-Lines . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. External Governor Parts and Speed Control Assembly . . . .

7-4. Flywheel and Ring Gear Assembly . . . . . . . . . . . . . .

7-5. Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . .

7-6. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Blower Wheel Assembly . . . . . . . . . . . . . . . . . . . .

7-8. Battery Charge Alternator . . . . . . . . . . . . . . . . . . . .

ENGINE INTERNAL ASSEMBLIES . . . . . . . . . . . . . . . . .

7-8.1. Engine Compression Test . . . . . . . . . . . . . . . . . . .

7-9. Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Piston and Connecting Rod . . . . . . . . . . . . . . . . . .

7-11. Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12. Oil Filter Adapter Assembly . . . . . . . . . . . . . . . . .

7-13. Oil By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . .

7-14. Gear Cover Assembly. . . . . . . . . . . . . . . . . . . . .

7-15. Governor Cup. . . . . . . . . . . . . . . . . . . . . . . . .

7-16. Camshaft Assembly and Tappets . . . . . . . . . . . . . . .

7-17. Crankshaft and Main Block Bearings . . . . . . . . . . . . .

7-18. Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . .

7-19. Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . .

7-20. Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE OF GENERATOR ASSEMBLY . . . . . . . . . . . .

DESCRIPTION AND FUNCTION . . . . . . . . . . . . . . . . . . . .

8-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Generator Maintenance . . . . . . . . . . . . . . . . . . . .

GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . .

9-1. General Information . . . . . . . . . . . . . . . . . . . . . .

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Engine Cooling System . . . . . . . . . . . . . . . . . . . . .

9-4. Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONAL TEST . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Generator and Generator Control Circuitry . . . . . . . . . .

9-6. Engine Control Circuitry . . . . . . . . . . . . . . . . . . . .

Page

7-1

7-1

7-1

7-1

7-1

7-1

7-5

7-6

7-6

7-6

7-8

7-9

7-9

7-10.1

7-13

7-19

7-19

7-19

7-21

7-25

7-25

7-27

7-30

7-41

7-41

8-1

8-1

8-1

8-1

8-1

9-1

9-1

9-1

9-1

9-1

9-1

9-1

9-1

9-1

9-1

iii
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

TABLE OF CONTENTS (CONT)

Page

CHAPTER

Section

Section

APPENDIX

INDEX

1 0 .

I .

I I .

A .

. . . . .

MATERIAL USED IN CONJUNCTION WITH DOD STANDARD

GENERATOR SET, 10KW DIESEL ENGINE, MODEL

MEP-003A AND MEP-112A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACOUSTIC SUPPRESSION KIT INSTALLATION . . . . . . . . . . . . . . . . .

10-2. Acoustic Suppression Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Preliminary Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Acoustic Suppression Kit Installation . . . . . . . . . . . . . . . . . . . . .

10-5. Post Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1

10-1

10-1

10-2

10-2

10-5

10-5

10-16

A-1

INDEX 1

iv Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure

l–l.

1–1.1

2–1.

2-2.

2-3.

2-4.

3-1.

5-1.

5-2.

5-3.

5-4.

5-5.

5-6.

5-7.

5-8.

5-9.

5-10.

5-11.

5–12.

5-13.

5-14.

6-1.

6-2.

6-3.

6-4.

6-5.

6-5.1.

6-6.

6-6.1.

6-7.

6-8.

6-9.

6-10.

6-11.

7-1.

7-2.

7-3.

7-3.1.

7-4.

7-5.

7-6.

7-7.

7–8.

7-8.1.

7-9.

7-10.

7-11.

7-12.

7-13.

7-14.

7-15.

7-16.

7-17.

7-18.

7-19.

7-20.

7-21.

LIST OF ILLUSTRATIONS

Title

Generator Set Electrical Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Electrical Schematic (MEP-l12A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting Engine from Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Engine and Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Starter Assembly (STYLE I). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Starter Assembly (STYLEII) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pinion Gear Stopper Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Armature for Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Armature for Shorted Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Armature for Open Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Commutator Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Armature Shaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Brush Spring Tension STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Solenoid Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Undercutting Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brush Replacement STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Pinion Clearance STYLE I Starter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Pinion Clearance STYLE II Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltage Regulator Schematic (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltage Regulator Schematic (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Box Wiring Harness (MEP-003A) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Box Wiring Harness (MEP-112A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Box Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Control Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Assembly (Switch, Receptacle and Circuit Breaker) . . . . . . . . . . . . . . .

Bridge Rectifier AssemblyA-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector FueI Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control Assembly and Governor Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Flywheel and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Port and Port Closing Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring Top Dead Center.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charge Alternator and Blower Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistively Loading the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Engine Assembly..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1-9

1-10.1

2-13

2-14

2-15

2-17

3-2

5-2

5-3

5-4

5-5

5-5

5-5

5-6

5-6

5-7

5-8

5-10

5-10

5-11

5-12

6-2

6-6

6-10

6-12

6-13

6-14

6-14.1

6-14.2

6-15

6-16.2

6-19

6-20

6-21

7-2

7-3

7-4

7-5

7-5

7-6

7-6

7-7

7-8

7-10

7-10.2

7-11

7-12

7-13

7-14

7-15

7-16

7-17

7-18

7-19

7-20

7-21

7-22

Change 8 v
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure

7–22.

7–23.

7-24.

7-25.

7-26.

7-27.

7-28.

7-29.

7-30.

7-31.

7-32.

7–33.

7-34.

7-35.

7-36.

7–37.

7-38.

7–39.

7-40.

7-41.

7-42.

7-43.

7-44.

7-45.

7-46.

7-47.

8-1.

8-2.

8-3.

8-4.

8-5.

9-1.

9-2.

10-1.

10-2.

10-3.

10-4.

10-5.

10-6.

Table

1-1.

1-2.

2-1.

2-2.

2-3.

6-1.

6-2.

6-3.

6-3.1.

6-4.

6-5.

6-6.

7-1.

9-1.

10-1.

vi

LIST OF ILLUSTRATIONS (CONT)

Title

Gear CoverComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Cover Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Cup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft and Camshaft Gear Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft End Play Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Pump Adjustment and Button Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Lower Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery Valve Test Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling Hydraulic Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Plunger Sleeve Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Testing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Port and Port Closing Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centering Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Frame Assembly Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exciter Rotor Assembly Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Rotor Winding Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting R3 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Engine Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relocation of Trailer Items to Accomodate ASK Modification . . . . . . . . . . . . . . . . . . . . . . .

Installation of Right Support, Rear Panel, and Rear Flap Assemblies . . . . . . . . . . . . . . . . . .

Installation of Left Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of Rear Closure Assembly and Exhaust Plenum Asscmblies . . . . . . . . . . . . . . .

Installation of Right Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of Left Panel, Side Closure, Front Panel and Top Panel Assemblies . . . . . . . . .

LIST OF TABLES

Title

Torque Values (Ft-Lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools, Test and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fabricated Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10KW Generator Set Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Box Wiring Harness (MEP-003A only) . . . . . . . . . . . . . . . . . . . . . . . . .

AC Output Control Box Wiring Harness (MEP-112Aonly) . . . . . . . . . . . . . . . . . . . . . . . . .

Terminal Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reconnection Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Bridge Assembly (60 Hz only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Button Code Letter and Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acoustic Suppression Kit Parts and Required Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change 8

Page

7-23

7-24

7-25

7-26

7-27

7-27

7-28

7-28

7-29

7-29

7-30

7–31

7-32

7-33

7-34

7-35

7-35

7-36

7-37

7-37

7-38

7-39

7-40

7-42

7-43

7-44

8-2

8-5

8-7

8-9

8-11

9-2

9-2

10-4

10-4

10-8

10-11

10-13

10-14

Page

1-3

1-4

2-1

2-2

2-4

6-3

6-5

6-7

6-8.1

6-9

6-15

6-17

7-40

9-2

10-2
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 1

INTRODUCTION

Section I. GENERAL

1-1. SCOPE.

This manual is for your use in maintaining the DOD

Standard Generator Set, 10KW Diesel Engine Driven,

Models MEP-003A and MEP-112A. It contains sections for general maintenance, including troubleshooting, and removal and installation of major

components, and maintenance of individual components

of the unit. Thoroughly familiarize yourself with the

unit before servicing or repairing unit.

1-2. LIMITED APPLICABILITY.

Some portions of this publication are not applicable

to all services. These portions are prefixed to indicate

the services to which they pertain: (A) for Army,

(F) for Air Force, (N) for Navy, and (MC) for Marine

Corps. Portions not prefixed are applicable to all

services.

1-3. MAINTENANCE FORMS AND RECORDS.

a. (A) Maintenance forms and records used by

Army personnel are prescribed in TM 38-750.

b. (F) Maintenance forms and records used by Air

Force personnel are prescribed in AFM-66-1 and the

applicable 00-20 Series Technical Orders.

c. (N) Navy users should refer to their service

peculiar directives to determine applicable maintenance forms and records to be used.

d. (MC) Maintenance forms and records used by

Marine Corps personnel are prescribed in TM 4700-

15/ 1.

1-6. DESCRIPTION.

1-4. REPORTING OF ERRORS.

Report of errors, omissions, and recommendations

for improvement of this publication by the individual

user is encouraged. Reports should be submitted as

follows:

a. (A) Army - DA Form 2028 directly to: Commander, US Army Troop Support and Aviation

Materiel Readiness Command, ATTN: DRSTSMTT, 4300 Goodfellow Boulevard, St. Louis, MO 63120.

b, (F) Air Force - AFTO Form 22 directly to:

Commander, Sacramento Air Logistics Center, ATTN:

MMEDT, McClellan Air Force Base, CA 95652, in

accordance with TO-00-5-1.

c. (N) Navy - by letter directly to: Commanding

officer, US Navy, Ships Parts Control Center, ATTN:

Code 783, Mechanicsburg, PA 17055.

d. (MC) Marine Corps - by NAVMC form 10772

directlv to: Commandant. US Marine Corps, ATTN:

Code L-MA-l, WASH DC 20380.

1-5. LEVELS OF MAINTENANCE ACCOMPLISHMENT.

a. (A, MC) Army and Marine Corps users shaIl

refer to the Maintenance Allocation Chart (MAC) for

tasks and levels of maintenance to be performed.

b. (F) Air Force users shall accomplish maintenance at the user level consistent with their capability

in accordance with policies established in AFM 66-1.

c. (N) Navy users shall determine their maintenance

levels in accordance with their service directives.

Section II. DESCRIPTION AND TABULATED DATA

1-7. TABULATED DATA.

A general description of the Diesel Engine Generator

Sets and information pertaining to the identification

a. General. This paragraph contains all maintenance

data pertinent to intermediate (field) (direct, general

plates are contained in the Operator and support) and depot maintenance personnel.

Organizational Maintenance Manual. Detailed

descriptions of the components of the Diesel Engine

Generator Sets are provided in the applicable b. Engine Generator Sets. Refer to Operator and

maintenance paragraphs of this manual. Organizational Maintenance Manual.

Change 2 1-1
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

c. Main Generator. Exciter field voltage andcurrent

versus load, see the following:

Exciter

Percent of Rated Load

d.

10-.8PF, 120 V Volt s Amps

o 17.8 0.96

25 21.7 0.56

50 25.5 0.66

75 29.8 0.77

100 34.0 0.87

125 38.7 1.0

Generator Frame Assembly.

Model . . . . . . . . . . . . . . . . . . . .MEP-003A

DOD Drawing No. . . . . . . . . . . . 72-5270

Number of Slots ........ . . . ...6 0

Pitch of Coil . . . . . . . . . . . . . . . . 1-11

Coil Groups . . . . . . . . . . . . . . ...12

Coils per Group . . . . . . . . . . . . . ...5

Turns per Coil Group . . . . . . . 5-5-5-5-5

Conductor . . . . . . . . . . . 8 strands of #18

AWG magnet wire

Resistance between lead. . . 0.115 ± 0.012 ohms

pairs T1

- T4, T2- T5, T3- T6

T 7- T1 0, T 8- T11 and T9- T1 2

at 25°C (87°F)

Model . . . . . . . . . . . . . . . . . . . .MEP-l12A

DOD Drawing No. . . . . . . . . . . . . . . 72-5272

Number of Slots . . . . . . . . . . . . . . . . . . . 108

Pitch of Coil . . . . . . . . . . . . . . . . . . . . . 1-4

Turns per Coil . . . . . . . . . . . . . . . . . . ...2

Conductor . . . . . . . . . . . . . . . 5strandsof #18

AWG magnet wire

Resistance between lead . . . 0.071± 0.007 ohms

pairs T1

- T4, T2- T5, T3- T6,

T 7

- T1 0, T8- T1l and T9- T1 2

at 25° C

e. Generator Rotor.

Model . . . . . . . . . . . . . . . . . . ..,MEP-003A

DOD Drawing No. . . . . . . . . . . . 72-5265

Air Gap . . . . . . . . . . . . ..0.090 to 0.106 in.

Number of Poles . . . . . . . . . . . . . . .4

Turns per Pole . . . . . . . . . . . . . . . 207

Conductor . . . . . . . . . . . . 1 strand of #14

AWG magnet wire

Connection . . . . . . . . . . . . . .. series

Resistance of Connected . . . 3.31 ± 0.33 ohms

Poles at 25° C (77° F)

Model . . . . . . . . . . . . . . . . . . . MEP-112A

DOD Drawing No. . . . . . . . . . . . . . . 72-5267

Air Gap . . . . . . . . . . . . . .. 0.030 to 0,048 in.

Number of Poles . . . . . . . . . . . . . . . . .. .24

Turns per Pole . . . . . . . . . . . . . . . . . . .55

Conductor . . . . . . . . . . . . .. 4 strands of #18

AWG magnet wire

Resistance of Connected . . .. 3.05 ± 0.305 ohms

Poles at 250° C

f. Engine. Refer to Operator and Organizational

Maintenance Manual.

g.

h.

i.

j.

Exciter Assembly.

MEP-003A MEP-112A

Frequency Regula- . . ± 1.8 ± 6.0

tion, Hz

Short Term . . . . . . . ± 1.2 ± 4.0

Steady State, Hz

Stability (30 sec)

Long Term . . . . . . . ±1.8 ± 6.0

Steady State, Hz

Stability (4 hrs)

Frequency Drift . . . . ± 1.2 ± 4.0

(8 Hr period), Hz

Exciter Stator.

DOD Drawing No. . . . . . . . . . . . 72-5240

Number of Poles ....... . . . . ... 8

Turns per coil . . . . . . . . . . . . ...400

Conductor . . . . . . . . . . . . l stand of #23

AWG magnet wire

Connection . . . . . . . . . . . . . .. series

Resistance at 25° C (87° F) . . 36.0 ± 3.6 ohms

Exciter Rotor.

DOD Drawing No. . . . . . . . . . . . 72-5220

Air Gap . . . . . . . . . . . . . . .052 to .064

Number of Slots . . . . . . . . . . . . . ..36

Pitch of Coil . . . . . . . . . . . . . . . . 1-4

Coil Groups . . . . . . . . . . . . . ..24

Coils per Group . . . . . . . . . . . . . ..2-1

Turns per Coil . . . . . . . . . . . . . ..11

Conductor . . . . . . . . . . . 1 strand of #17

AWG magnet wire

Resistance between . . . . . 0.677 ± 0.068 ohms

T1

- T2, T2- T3 and T1- T3

at 25°C (87°F)

Circuit Breaker.

DOD Drawing No. . . . . (MEP-003A) 72-5173

Construction (MEP-112A) 72-5174

Handle Spacers . . . . . . . . . . . aluminum

Handle Tie Bars . . . . . . . . . . aluminum

Mounting Insert . . . . . . . . . . . . . steel

Washer . . . . . . . . . . . . external tooth

Studs . . . . . . . . . . brass with silver or

tin plated

Handle Tie Pin . . . . . corrosion resistant

steel

Type . . . . . . . . . . . . . . . . . . relay trip

Voltage . . . . . . . . . . . . . . ..250 vac

Frequency . . . . . . . . (MEP-003A) 60 Hz

(MEP-112A) 400 Hz

Interrupting Capacity . . . . . . . . . . . 5000A

Relay Coil . . . . . . . . . . . . . calibrated to

carry 0.82A

Trip . . . . . . . . . . . . . 1.13A 6 ± 3 min

Trip . . . . . . . . . . 3.00A instantaneously

Maximum Contact Capacity . . . . . . . . 104A

Temperature Range . . . . . . . 54° C thru 85° C

129° F thru 185° F

1-2 Change 2
k. Engine Accessories.

(1) Fuel injection pump.

Manufacturer . . . . . . . . . . . . .. Onan

Model . . . . . . . . . . . . . . . .147-0333

Type . . . . . . . . . . PSU, single plunger

multi outlet

Drive Type . . . . . . . . . . . .gear and cam

Mounting . . . . . . . . . . . block mounted

(2) Fuel transfer pumps. Refer to Operator and

Organizational Maintenance Manual.

(3) Electric starter. Refer to Operator and

Organizational Maintenance Manual.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(4) Battery charging alternator. Refer to Operator

and Organizational Maintenance Manual.

(5) Fuel solenoid valve.

DOD Drawing No. . . . . . . . . . . . 72-5069

volts . . . . . . . . . . . . . . . . . 24 vdc

Watts . . . . . . . . . . . . . . . . . . 12 w

Input Pressure . . . . . . . . . . . ..20 psi

Orifice Size . . . . . . . . . . . . . 0.187 inch

(6) Oil pump.

Type . . . . . . . . . . . . . . . gear driven

1. Acoustic Suppression Kit.

Manufacturer . . . . . . . . . . . . . . . . . . .IAC

Model . . . . . . . . . . . . . . . . . . . MEP-003AAS

Type . . . . . . . . . . . . . . . . sound absorptive

cover

Change 6 1-2.1/(1-2.2 blank)

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 1-1. Torque Values (Ft-Lb Dry)

Torque Range (Cadmium Plated) (Ft-Lb Dry)

Item Min. Max.

Connecting rod bolt . . . . . . . . . . . . . . 27 29

Cover-rocker box . . . . . . . . . . . . . . 7 8

Exhaust manifold nuts . . . . . . . . . . . . 11* 13*

Flywheel mounting screw . . . . . . . . . . . 54 58

Gearcase cover . . . . . . . . . . . . . . . . 15 17

Rear bearing plate . . . . . . . . . . . . . . 40** 45**

Rocker arm nut (prevailing torque locknut). 4*** 10***

Rocker arm stud . . . . . . . . . . . . . . . 35 40

Oil pump mounting screws . . . . . . . . . . 13 17

Oil base mounting screws . . . . . . . . . . 42  47** **

Oil filter base mounting screws . . . . . . . 18 20

Cylinder head bolt . . . . . . . . . . . . . . 44* 46*

Oil cooler mounting screws . . . . . . . . . 20 22

Blower wheel mounting screw . . . . . . . . 65 70

Intake manifold mounting screws . . . . . . 13 15

Injector nozzle mounting screws . . . . . . . 17 18

Glow plug . . . . . . . . . . . . . . . . . . . 10* 15*

Governor arm locking screw . . . . . . . . . 32 (in. lb.) 36 (in. lb.)

Damper blower wheel assembly nut . . . . . 28 30

Backplate screw (hex-socket flathead) . . . . 75 (in. lb.) 85 (in. lb.)

Center main bolt . . . . . . . . . . . . . . . 97 102

High temperature cutout switch . . . . . . . 50 (in. lb.) 60 (in. lb.)

Fuel supply line nut

Fuel return line fitting***** 16 18

Anti Seize Compound.

Apply MIL-S-22473C, Grade CV, to threads.

 Torque specifications to be used only to determine if used locknuts meet new part tolerances.

 Torque these screws twice.

Tighten to 1/6 turn beyond a hand tightened snug fit.

Change 6 1-3
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 1-1. Torque Values (Ft-Lb Dry) (Cont’d)

Torque Range (Cadmium Plated) (Ft-Lb Dry)

Item Min. Max.

Acoustic Suppression Kit

Right Support Assembly Mounting Screws . . . . 24 28

Left Support Assembly Mounting Screws . . . . . 24 28

Rear Panel Assembly Mounting Screws . . . . . . 14 18

Rear Flap Assembly Mounting Screws . . . . . . . 14 18

Rear Closure Assembly Mounting Screws . . . . . 14 18

Side Closure Assembly Mounting Screws . . . . . 14 18

Exhaust Plenum Assembly Mounting Screws . . 14 18

Left Panel Assembly

Support Mounting Screws . . . . . . . . . . . . . . 16 (in. lb.) 20 (in. lb.)

Side Closure Mounting Screws . . . . . . . . . . 14 18

Right Panel Assembly

Support Mounting Screws . . . . . . . . . . . . . . 16 (in. lb.) 20 (in. lb.)

Rear Closure Mounting Screws . . . . . . . . . . 14 18

Rear Panel Mounting Screws . . . . . . . . . . . 16 (in. lb.) 20 (in. lb.)

Front Panel Assembly Mounting Screws . . . . . 16 (in. lb.) 20 (in. lb.)

Top Panel Assembly

Side & Rear Closure Mounting Screws . . . . 14 18

Left, Right & Front Panel

Mounting Screws . . . . . . . . . . . . . . . . . . . 16 (in. lb.) 20 (in. lb.)

1-4 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 1-2. Repair and Replacement Standards

(All values in inches unless otherwise specified.)

Component

CYLINDER BLOCK:

Cylinder bore diameter

Cylinder bore out of round

Cylinder bore taper

Main bearing bore - less bearings

Camshaft bearmg bore - less

bearings

Front

Center

Rear

Valve tappet bore

CRANKSHAFT:

Main bearing journal diameter

Main bearing journal clearance

Main bearing journal out of round

Main bearing journal taper

Connecting rod journal diameter

Connecting rod journai out of round

Connecting rod journal taper

Fillet radii

*Crankshaft main bearing clearance

Crankshaft thrust clearance

Seal surface diameter - rear

Seal surface diameter - front

CONNECTING ROD:

Length -cto c

Bearing bore - less bearings

Bearing to crankshaft clearance

Connecting rod side clearance

Manufacturer Dimensions

and Tole

Minimum

3.4993

2.4365

2.3745

1.7500

1.3120

0.8755

2.2427

0.0012

2.0597

0.1100

0.0024

0.010

1.8740

1.6870

5.9980

2.1871

0.0010

0.0020

rance s

Maximum

3.5005

0.001

0.001

2.4375

2.3755 

1.7510

1.3130

0.8765

2.2435

0.0037

0.0005

0.0004

2.0605

0.0005

0.0004

0.1200

0.0049

0.015

1.8750

1.6875

6.002

2.1876

0.0030

0.0160

Maximum Allowable

Wear Limit

0.005

0.001

0.002

2.4375

2.3755

1.7510

1.3130

0.8775

0.001

0.0047

0.001

0.0015

0.002

0.001

0.0015

0.1200

0.0054

0.015**

0.0050

0.0050

6.002

2.1886

0.0040

0.0160

* Replacement Bearing Only

* * Shim Controlled

Change 6 1-4.1/(1-4.2 blank)

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 1-2. Repair and Replacement Standards (Cont)

Manufacturer Dimensions

and Tolerances

Maximum Allowable

Component Minimum Maximum Wear Limit

CONNECTING ROD (Cont):

Connecting rod side clearance 0.0020 0.0160 0.0160

Piston pin bushing bore - less 1.043 1.045 1.0455

bushing

Piston pin bushing bore 0.9903 0.9906 0.001

CAMSHAFT:

Bearing journal diameter

Front 2.2500 2.2505 0.002

Rear 1.1875 1.1880 0.002

Lobe diameter - base to tip 1.185 1.189 0.005

Journal runout in vee blocks 0.004

Bearing clearance 0.0012 0.0037 0.0057

End Thrust 0.0070 0.0390 0.0450

Backlash camshaft to crank gear 0.005 0.0100 0.0120

PISTON:

Clearance in cylinder bore (pull on 0.0062 0.0082 0.010

1/2 x 0.0050 ribbon)

Piston pin bore 0.99005 0.99025 0.9903

Width of ring groove - top 0.097 0.098 0.005

Width of ring groove - 2nd & 3rd 0.0965 0.0975 0.005

compression

Width of ring groove - oil control 0.1880 0.1895 0.005

PISTON PIN:

Length 2.988 3.003 N/A

Diameter 0.9899 0.9901 0.001

Clearance in piston 0.0005 0.0025 0.0003

Clearance in connecting rod 0.0002 0.0007 0.0008

PISTON RING:

Clearance in groove - top 0.0035 0.0075 0.0100

Clearance in groove - 2nd & 3rd 0.0030 0.0050 0.0080

compression

1-5
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 1-2. Repair and Replacement Standards (Cont)

Manufacturer Dimensions

and Tolerances

Maximum Allowable

Component Minimum Maximum Wear Limit

PISTON RING (Cont):

Clearance in groove - oil control 0.0020 0.0030 0.0050

Gap 0.0100 0.0200 0.0400

VALVE, INTAKE:

Head diameter 1.307 1.317 N/A

Stem diameter - tapered 0.3391/0.3381 0.3420/0.3410 0.002

Stem to guide clearance 0.0030/0.0050 0.0012/0.0032 0.0100

Stem to rocker arm clearance Cold 0.010 0.010 adjustable

Seat diameter in head 1.361 1.362 N/A

Seat width in head 1/16 3/32 1/8

Top of valve recessed below 0.433 0.439 0.500

cylinder head deck

Valve seat angle 45° N/A 45°

Valve Face Angle 44° N / A 44°

VALVE, EXHAUST:

Head diameter 1.307 1.317 N/A

Stem diameter 0.3405 0.3415 0.002

Stem to guide clearance 0.0030 0.0050 0.0100

Stem to rocker arm clearance Cold 0. 007 0.007 adjustable

Seat diameter in head 1.361 1.362 N/A

Seat width in head 3/64 1/16 1/8

Top of valve recessed below 0.433 0.439 0.500

cylinder head deck

Valve seat angle 45o N/A 45o

Valve Face Angle 45° N / A 45°

VALVE GUIDE:

Length Exhaust 2

Intake 1-25/32

Outside diameter 0.4690 0.4695 0.4695

Bore diameter - intake - ream 0.3425 0.3435 0.003

Bore diameter - exhaust - ream 0.3445 0.3455 0.003

Height above cylinder head deck

Intake 11/32 N/A

Exhaust 5/8 N/A

1-6
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 1-2, Repair and Replacement Standards (Cont)

1-7
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 1-2. Repair and Replacement Standards (Cont)

Manufacturer Dimensions

and Tolerances

Maximum Allowable

Component Minimum Maximum Wear Limit

FLYWHEEL:

Face runout, total 0.0053

Pilot bore eccentricity 0.0020

FLYWHEEL HOUSING:

Attaching face deviation 0.0113

Housing bore eccentricity 0.005

ROCKER ARM MECHANISM:

Tappet adjusting screw torque 4 ft-lbs 10 ft-lbs

CYLINDER HEAD:

Warpage (longitudinally) 0.001 0.0015

Warpage (laterally) 0.001 0.0015

(7) Oil Cooler. Refer to Operator an d m. Engine Repair and Replacement Standards. Table

Organizational Maintenance Manual. 1-2 lists manufacturer’s sizes, tolerances, and maximum allowable wear and clearances.

1. Safety Devices. n. Schematic Wiring Diagrams. Figure 1-1 shows

(1) High temperature switch. Refer to Operator

the schematic wiring diagram of the power plant.

and Organizational Maintenance Manual. o. Torque Values.

(2) Low oil pressure switch. Refer to Operator (1) Table 1-1 lists specific torque values.

and Organizational Maintenance Manual.

(2) All torque values are calculated for oil lubri-

(3) Fuel level switch (day tank). Refer to Oper- cated threads. Increase this value by 10 percent when

ator and Organizational Maintenance Manual. threads are not Lubricated.

1-8
Figure 1-1.

TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B-34

1-9/(1-10 blank)
TM-6115-585-34

NAFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

1-10.1/(1-10.2 blank)

Figure 1-1.1.
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 2

GENERAL MAINTENANCE INSTRUCTIONS

Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, AND DIAGNOSTIC

EQUIPMENT (TMDE), AND SUPPORT EQUIPMENT

2-1. REPAIR PARTS. Table 2-1 contains a list of all special tools, test and

Repair parts and equipment are listed and illustrated

support equipment needed to maintain this unit.

in the repair parts and special tools list manual 2-3. FABRICATED TOOLS AND EQUIPMENT.

covering intermediate (field) (Direct and General Support) and depot maintenance for this Generator Set. Table 2-2 contains fabrication instructions for all

2-2. TOOLS AND EQUIPMENT.

tools which must be fabricated by intermediate or

depot personnel for maintenance of this unit.

Table 2-1. Special Tools, Test and Support Equipment

Item

Delivery valve test fixture

Pump mounting fixture

Plunger spring compression

tool

Centering sleeve

Compression tester

gage

Compression adapter

NSN

Reference

No.

(01843)*

TSE-76226

TSE-76215

TSE-773

4910-00-870-6283

4910-00-870-2127

Reference

Fig. No.

7-36

7-35

7-47

7-8.1

7-8.1

Para. No.

7-18

7-18

7-18

7-20

7-8.1

7-8.1

*Federal supply code for the manufacturer.

Use

Testing fuel injection

pump delivery valve

Mount fuel injection

pump in vise for

disassembly

Remove and install

spring seat

Assembly of fuel

injector

Test engine

compression

Test engine

compression

Table No.

2-2

Change 3 2 -1
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 2-2. Fabricated Tools and Equipment

Nomenclature Reference No. or NSN Material Required

Pump mounting fixture 0.375” cold rolled steel

Fabrication Instructions:

Fabricate fixture as shown below. Drill “F” (0.255 in.-0.262 in.) depth thru countersink 60° incl. to

0.332 in. diameter. Tap 0.3125-18 UNC-2B depth thru. Two holes located within 0.005 in. of true

position.

Sketch or Diagram:

2-2
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 2-2. Fabricated Tools and Equipment (Cont)

Nomenclature Reference No. or NSN Material Required

Valve spring depressor 1/4” cold rolled steel

Fabrication Instructions:

Fabricate tool to dimensions shown below.

Sketch or Diagram:

Nomenclature Reference No. or NSN Material Required

Compression adapter 5/16” cold rolled steel

mounting studs

Fabrication Instructions:

Fabricate compression adapter mounting studs (2 required) to the dimensions shown below.

Sketch or Diagram:

Change 3 2-3
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 2-2. Fabricated Tools and Equipment (Cont)

Nomenclature Reference No. or NSN Material Required

Crankshaft gear driver Steel pipe 3/16” wall thickness

Fabrication Instructions:

Fabricate tool to dimensions shown below by sawing pipe to correct length.

2-4

Sketch or Diagram:
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 2-2. Fabricated Tools and Equipment (Cont)

Nomenclature Reference No. or NSN Material Required

Camshaft/crankshaft Steel, round, CD

gear puller ring

Fabrication Instructions:

Make puller according to dimensions shown below.

Sketch or Diagram:

Section II. TROUBLESHOOTING

2-4. GENERAL. 2-5. MALFUNCTIONS NOT CORRECTED BY

USE OF THE TROUBLESHOOTING

This section contains troubleshooting information for TABLE.

locating and correcting operating troubles which may

develop in the Generator Set. Each malfunction for an This manual cannot list all malfunctions that may ocindividual component unit, or system is followed by cur, nor all tests or inspections and corrective actions.

a list of tests or inspections which will help you to If a malfunction is not listed or cannot be corrected

determine probable causes and corrective actions to by listed corrective actions, notify your supervisor.

take. You should perform the tests/inspections and

corrective actions in the order listed.

Change 5 2 - 5
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05658B-34

Table 2-3. Troubleshooting

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

1. STARTER MOTOR DOES NOT TURN-HIGH CURRENT DRAW.

Step 1. Check starter for grounded switch, terminals, or field (paragraph 5-2).

Replace any grounded component.

Step 2. Check for frozen armature shaft bushing (paragraph 5-2).

Replace bushing and, if necessary, armature.

2. STARTER DOES NOT TURN-NO CURRENT DRAW.

Step 1. Check for open armature windings (paragraph 5-2).

Replace armature if necessary.

Step 2. Check for open starter field windings (paragraph 5-2).

Replace field windings if necessary.

Step 3. Check for broken or weak brush springs (paragraph 5-2).

Replace brush springs if necessary.

Step 4. Check for worn commutator (high mica) (paragraph 5-2).

Refinish commutator or replace armature (including commutator).

3. SLOW STARTER SPEED.

Step 1. Check for dirty commutator (paragraph 5-2).

Clean or refinish commutator.

Step 2. Check for worn armature shaft bushings (paragraph 5-2).

Replace bushings and, if necessary, armature.

Step 3. Check for burned solenoid contacts (paragraph 5-2).

Replace solenoid.

Step 4. Check for open or shorted starter field windings (paragraph 5-2).

Replace windings if necessary.

Step 5. Check for shorted generator stator windings (paragraph 8-2).

Replace stator windings.

Step 6. Check for worn generator end bearing (paragraph 8-2).

Replace bearing if necessary.

Step 7. Check for worn engine crankshaft, rod, and camshaft bearings (paragraph 7-17).

Replace bearings as necessary. Repair or replace other worn compments

as necessary.

2-6
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 2-3. Troubleshooting (Cont)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

4. STARTER WILL NOT ENGAGE FLYWHEEL.

Step 1. Check starter clutch (bendix) and pinion (paragraph 5-2).

Repair or replace as necessary.

Step 2. Check for damaged ring gear (paragraph 7-4).

Replace ring gear if necessary.

5. ENGINE WILL NOT START WHEN CRANKED.

Step 1. Check for faulty injection caused by dirty fuel.

Replace with clean fuel. Service fuel filters. Clean and if necessary repair or

replace fuel injection nozzle (paragraph 7-20).

Step 2. Check for poor compression.

See malfunction 14.

Step 3. Incorrect timing.

Retime engine (paragraph 7-18).

6. ENGINE MISFIRES.

Step 1.

Step 2.

Step 3.

Step 4.

Check for poor compression.

See malfunction 14.

Check for defective or dirty injection nozzles (paragraph 7-20).

Clean or replace nozzles.

Check for broken valve spring (paragraph 7-9).

Replace broken springs.

Check cylinder head assembly for build-up of carbon (paragraph 7-9).

Clean carbon from cylinder head assembly.

7. LOW ENGINE POWER.

Step 1. Check for poor compression.

See malfunction 14.

Step 2. Check for incorrect timing,

Adjust injection timing if necessary (paragraph 7-18).

8. LOW OIL PRESSURE.

Step 1. Check to see if oil by-pass is stuck open (paragraph 7-13).

Clean or replace oil by-pass valve and spring.

2-7
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 2-3. Troubleshooting (Cont)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

8. LOW OIL PRESSURE (CONT).

Step 2. Check for worn oil pump (paragraph 7-11).

Replace pump.

Step 3. Check for worn engine bearings (paragraph 7-17).

Replace worn bearings.

9. HIGH OIL PRESSURE

Step 1. Check to see if oil by-pass is stuck closed (paragraph 7-13).

Clean or replace oil by-pass valve and spring.

Step 2. Check for clogged oil passages.

Clean all oil lines and passages.

10. EXCESSIVE OIL CONSUMPTION.

Step 1. Check for worn valve guides (paragraph 7-9).

Replace guides, valves, and seals.

Step 2. Check for worn or sticking piston rings (paragraph 7-10).

Replace rings if necessary.

Step 3. Check for air leaks to crankcase.

Replace gaskets and seals as necessary.

11. BLACK SMOKEY EXHAUST AND EXCESSIVE FUEL CONSUMPTION

Step 1. Check for incorrect timing (paragraph 7-18).

Adjust injection timing if necessary.

Step 2. Check for faulty injection pump or nozzles (paragraphs 7-18 and 7-20).

Repair, overhaul, rebuild, or replace pump and nozzles as necessary.

Step 3. Check valve condition (paragraph 7-9).

Replace worn valves.

12. TAPPING OR CLICKING SOUND FROM CYLINDER HEAD.

Step 1. Check for too great a valve clearance (paragraph 7-9).

Adjust clearance.

Step 2. Check for broken valve spring (paragraph 7-9).

Replace broken springs.

2-8
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 2-3. Troubleshooting (Cont)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

13. METALLIC KNOCKING, CLICKING, OR POUNDING FROM CRANKCASE OR CYLINDER BLOCK.

Step 1. Check for worn or loose comecting rod bearings (paragraph 7-10).

Replace bearings if necessary.

Step 2. Check for loose piston and connecting rod assembly (paragraph 7-10).

Repair or replace assembly.

14. LOW ENGINE COMPRESSION.

NOTE

Normal cylinder pressure is between 350 and 450 psi depending upon engine condition. Maintenance should be considered

if pressure is below 325 psi or if there is a 15 percent or

more difference between cylinders.

Step 1. Check for loose cylinder head (paragraph 7-9).

Properly tighten head.

Step 2. Check for leaky head gasket (paragraph 7-9).

Replace gasket.

Step 3. Check for broken valve spring (paragraph 7-9).

Replace broken springs.

Step 4. Check for sticking valves (paragraph 7-9).

See sticking valve section below.

Step 5. Check for leaking valves (paragraph 7-9).

Clean and, if necessary, regrind valves and valve seats.

Step 6. Check for worn or sticking piston rings (paragraph 7-10).

Replace rings if necessary. Check condition of cylinder walls.

Step 7. Check for worn cylinder walls and pistons (paragraphs 7-10 and 7-19).

Refinish cylinder walls. Repair or replace pistons.

15. STICKING VALVES.

Step 1. Check for dirty, scored, or gummy valve stems or guides (paragraph 7-9).

Clean stems and guides. If necessary, replace guides.

Step 2. Check for weak or broken springs (paragraph 7-9).

Replace springs.

2-9
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 2-3. Troubleshooting (Cont)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

15. STICKING VALVES (CONT).

Step 3. Check clearance between valve stem and guide (paragraph 7-9).

Correct clearance.

16. ENGINE RUNS NORMALLY BUT GENERATOR HAS NO OUTPUT.

Step 1.

Step 2.

Step 3.

Step 4.

Step 5.

Step 6.

Step 7.

Step 8.

Check voltage regulator (paragraph 6-6).

Repair or replace regulator.

Check exciter field (stator) for open or shorted windings (paragraph 8-2).

Replace stator if necessary.

Check diodes on exciter rotor (paragraph 8-2).

Replace diodes if necessary.

Check generator field (rotor) for open or shorted windings

Replace rotor if necessary.

Check generator rotor flashing circuit (paragraph 6-9).

Replace diode CR2 or bridge rectifier.

(paragraph 8-2).

Check generator stator for open, shorted, or grounded windings (paragraph 8-2).

Replace stator if necessary.

Check exciter rotor for open, shorted, or grounded windings (paragraph 8-2).

Replace exciter rotor if necessary.

Check bridge assembly A4 for defective resistor or diodes (paragraph 6-9).

Replace defective resister or diodes

17. ENGINE RUNS NORMALLY BUT GENERATOR HAS LOW OUTPUT.

Step 1. Check voltage regulator (paragraph 6-6).

Adjust, repair, or replace regulator.

Step 2. Check generator stator for open or shorted windings (paragraph 8-2).

Replace stator.

Step 3. Check exciter rotor for shorted windings (paragraph 8-2).

Replace rotor.

Step 4. Check diodes on exciter rotor (paragraph 8-2).

Replace diodes as necessary.

2-10
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 2-3. Troubleshooting (Cont)

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

18. HIGH GENERATOR OUTPUT VOLTAGE (NO LOAD).

Step 1. Check for voltage regulator failure. Remove voltage regulator lead wire X39C16 from terminal 17.

If voltage goes even higher, the voltage regulator is good.

Test and repair defective regulator (paragraph 6-6).

Step 2. Check voltage adjust rheostat (R1).

Replace rheostat (Rl) if necessary.

Step 3. Check current voltage transformer (CVTI) (paragraph 6-9b(7)).

Replace bad transformer.

Step 4. Check transformer T2 (paragraph 4–38 (15), TM 5-6115-585-12).

Replace bad transformer.

19. FREQUENCY METER (M3) FAILS TO REGISTER.

Step 1. Check transformers T1 and T2 (paragraph 4-38 (14) and (15), TM 5-6115–585–12).

Replace bad transformers.

Step 2. Check frequency meter and transducer (paragraph 6-4).

Replace bad meter or transducer.

20. BATTERIES DO NOT CHARGE.

Step 1. Check battery charging alternator stator (paragraph 7-8).

Replace bad stator.

Step 2. Check battery charging alternator rotor (paragraph 7-8).

Replace bad rotor.

Step 3. Check regulator-rectifier assembly (TM 5-6115-585-12, paragraph 4-27).

Replace bad regulator-rectifier.

Change 6 2-11
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Section III. GENERAL MAINTENANCE

2-6. GENERAL MAINTENANCE.

This section contains general maintenance instructions which are the responsibility of direct support

and general support maintenance personnel. You will

find that these instructions apply to several assemblies or components. They would otherwise have to

be repeated throughout the chapter.

2-7. GENERAL MAINTENANCE PROCEDURES,

a. Work Guidelines.

(1) Make sure the work area is clean before you

disassemble the pump or engine.

(2) Make sure that materials needed for the

maintenance task are at hand. These may include

cleaning solvents, lubricants, buckets, or other containers for cleaning or keeping components separated,

clean wiping cloths, and, of utmost importance, the

proper tools.

DRY CLEANING SOLVENT, P-D-680 or P-S861, used to clean parts is potentially dangerous to personnel and property. Avoid repeated

and prolonged skin contact. DO NOT use near

open flame or excessive heat. Flash point of

solvent is 100o to 138° F (38° to 60° C).

(3) Clean the exterior of the engine and pump

before disassembly to keep foreign matter from

bearings, gears, and other machine-surfaced parts

which are subject to scoring and other such damage.

Use a cloth dampened with cleaning solvent (fed. spec.

P-D-680).

Compressed air used for cleaning and drying

purposes can create airborne particles that

may enter the eyes. Pressure shall not exceed

30 psig and use only with adequate chip

guards and goggles.

(4) If compressed air is used to clean parts, you

should make sure it is free of dirt and other contaminants.

(5) Protect disassembled parts from dust, blowing

sand, and moisture which can cause rapid wear and

deterioration of bearings, gears, and other machine

parts.

b. Seals and Gaskets. Replace seals and gaskets of

all components disassembled. This will greatly reduce

the possibility of leaking and will help prevent the

entry of dust and dirt after reassembly.

c. Care of Bearings.

(1) Clean ball and roller bearings by placing them

in a wire basket and immersing in a container of

fresh cleaning solvent. Agitate the bearings in the

solvent to remove all traces of old lubricant.

(2) After cleaning the bearings, dry them with

clean compressed air. Take care to prevent spinning

the bearings when using a compressed air jet.

(3) Dip the cleaned bearings in clean engine oil

and immediately wrap them in lint-free paper to

protect them from dust and other foreign matter.

d. Replacing Electronic Components.

(1) Tag wires before removal to facilitate proper

reconnection.

(2) When soldering use heat sink between soldering pencil and electronic component to prevent damage

to the component.

(3) Do not use excessive heat when soldering on

printed circuit boards to prevent damage to board.

e. Fuel System Maintenance. The fuel injectors and

fuel pump are manufactured to extremely tight tolerances. Even small amounts of dust or water in the

fuel system can damage these components. Consequently it is of great importance that dirt be kept out

of the fuel lines and fittings during disassembly and

assembly. All openings should be taped, plugged, or

capped immediately after disassembly. If dirt does

accidentally enter a component, it should be washed

in clean fuel oil before reassembly.

Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS

2-8. CONTROL CUBICLE. 2-9. ENGINE ASSEMBLY.

a. Removal. Refer to Operator and Orguizational

Matitanance Manual.

a. Remove. On ASK equipped generators, refer to the Operator

and Organizational Maintenance Manual, remove cover assembly,

and perform the following steps.

b . Installation . Refer to Operator an d

Organizational Maintenance Manual. (1) Disconnect and remove batteries.

2-12 Change 6
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NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(2) Tag and disconnect battery cables and ground (7) Disconnect and remove fuel tank.

cable from starter.

(3) Tag and disconnect wiring harness and electrical (8) Disconnect speed adjustment assembly (see

leads from engine. figure 2-1). Loosen nut (1) and lockwasher (2) and slide

from bracket (5).

(4) Disconnect air cleaner holes from shutter assembly and intake manifold. Remove air cleaner and bracket (9) Connect a suitable lifting

assembly from top of generator. engine.

(5) Disconnect fuel line from fuel filter at fuel

check valve. Disconnect flexible fuel return line to top (10) Disconnect engine from

of fuel injection pump. See figure 2-2.

device and support

generator assembly.

(6) Disconnect oil drain hose from mounting on (a) Remove generator screen-guard. Refer to

skid-base and drain oil. Operator and Organizational Maintenance Manual.

Figure 2-1. Speed Control Assembly

2-13
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 2-2. Disconnecting Engine from Generator

housing.

Manual.

(b) Remove center plug from grille on blower

Refer to Operator and Organizational Maintenance

(c) Using a 5/8” socket wrench on hex head

capscrew at center of blower wheel, rotate engine clockwise until one of the four sets of screws (1, figure 2-2)

attaching generator fan (4) and coupling plate to engine

flywheel is accessible thru opening in generator housing

(8). Straighten locking tabs and remove the two screws

(1) and the locking plate (2) and pressure plate (3).

(d) Rotate engine an additional 90° and remove

second set of screws. Continue until all four sets of screws

(1) are removed.

(e) Remove twelve nuts (5) and lockwashers

(6) attaching generator housing (8) to engine(7).

(11) Remove four screws (3, figure 2-3), lockwashers (5), flatwashers (4) and nuts (6) attaching each

engine mount (2) to skid-base (7). Lift engine free of

Generator Set.

b. Installing Engine-Generator Assembly.

(1) Attach generator to engine.

(a) Install two 1/4-20 x 2 in. pilot studs into

the engine flywheel (9, figure 2-2) in two holes that are

180° apart.

(b) Align fan (4), adapter plate and flywheel

(9) using pilot studs.

(c) Install four screws (1), locking plate (2),

pressure plate (3) attaching fan and adapter to flywheel (9).

(d) Remove pilot studs and install remaining

screws (1), locking plates (2) and pressure plate (3).

(e) Bend locking plates (2) to lock all screws (1).

(f) Install twelve nuts (5) and lockwashers (6)

to attach generator housing (8) to engine (7).

(g) Check engine lifting bracket for proper torque

of 50 foot-pounds.

(2) Lift engine generator assembly into place on

skid-base and install screws (3, figure 2-3), lockwashers

(5), flatwashers (4) and nuts (6) to attach engine mounts

to skid base.

(3) Attach engine speed control (3, figure 2-1) to

bracket (5) and tighten nut (1).

(4) Refer to Operator and Organizational Maintenance Manual and proceed as follows:

(a)

removed.

(b)

(c)

base.

(d)

tion pump.

(e)

(f)

Install generator

Install fuel tank.

Connect oil drain

Connect fuel lines

screen-guard if previously

hose to mounting on skidto fuel fiiter and fuel injecInstall air filter assembly.

Reconnect previously tagged wire harnees to

engine (see schematic figure 1-1).

(g) Connect cables to starter.

(h) Install batteries and reconnect.

2-14 Change 5
TM5-6115-585-3 4

NAVFAC P-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-3 4

Figure 2-3. Lifting Engine 2-15 
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

c. Installing Engine.

(1) This installation procedure is to be followed

if the engine has been removed and the generator has

been left mounted on the skid-base.

(2) Lift engine into place on skid-base using

engine lifting bracket (8, figure 2-3). Leave about a

6 inch space between the generator and the engine.

(3) Loosen generator mounting screws (9, figure

2-4).

(4) Mount generator to engine as follows:

(a) Install two 1/4-20 x 2 in. pilot studs into

the engine flywheel (9, figure 2-2) in two holes that

are 180° apart.

(b) Align fan (4), adapter plate and flywheel (9)

using pilot studs.

(c) Install four screws (l), locking plate (2),

pressure plate (3) attaching fan and adapter to flywheel (9).

(d) Remove pilot studs and install remaining

screws (l), locking plates (2) and pressure plate (3).

(e) Bend locking plates (2) to lock all screws

(l).

(f) Install twelve nuts (5) and lockwashers (6)

to attach generator housing (8) to engine (7).

(5) Tighten generator mounting screws (9, figure

2-4).

(6) Attach engine supports (16, figure 2-4) to

skid-base (19) with screws (12), flatwashers (13),

lockwashers (14) and nuts (15).

(7) Perform step (4) of paragraph 2-9, b above.

(8) On ASK equipped generators, refer to Operator and

Organizational Maintenance Manual and replace cover assembly.

2-10. GENERATOR ASSEMBLY.

Engine lifting bracket is for lifting engine

alone. If engine and generator assembly are

lifted as one unit, use set lifting eye (18,

figure 2-4).

a. Remove. On ASK equippad generators, refer to Operator and

Organizational Maintenance Manual and remove cover assembly.

Generator assembly is removed by first removing engine and

generator assembly as one unit, then removing generator assembly

from engine.

(1) Disconnect three wiring assemblies from

connectors (1, figure 2-4) at ac output cubicle (2).

Disconnect generator ground at ground stud (3).

(2) Disconnect four screws (5), lockwashers (7),

and flatwashers (8) attaching generator support (4) to

generator and lift engine and generator assembly (17)

free of skid-base (19)

(3) Properly support engine and generator assembly and disconnect generator from engine assembly

as given in paragraph 2-9.

b. Install. Install engine and generator assembly as described

in paragraph 2-9, b. Connect three wiring assemblies to connectors

(1, figure 2-4) at ac output cubicle (2). Connect generator ground

at ground stud (3). On ASK equipped generators, refer to Operator

and Organizational Maintenance Manual and replace cover assembly.

2-16 Change 6
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 2-4. Lifting Engine and Generator Assembly

2-17/(2-18 blank)

TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 3

MAINTENANCE OF COOLING SYSTEM

Section I. DESCRIPTION AND FUNCTION

3-1. GENERAL. ator and forces it out openings near the engine. The

engine air outlet uses a shutter assembly to control

engine temperature. A thermostatic element controls

The engine has a pressure air cooling system. Fins shutter opening which limits air flow when the engine

on the engine blower draw air into the front of the is cold. When the engine air temperature reaches

engine housing and force it past the cylinders and out approximately 120° F, (49” C) the shutters begin to

the right side of the engine. A separate blower on the open. The shutters are completely open at 140° F

generator rotor draws air into the rear of the gener- (60° C) under full rated load.

Section II. MAINTENANCE

3-2. ENGINE COOLING SYSTEM.

a. Inspect on equipment (see figure 3-1). On ASK equipped

generators, refer to Operator and Organizational Maintenance

Manual and remove cover assembly and exhaust plenum.

(1) Shutter Assembly. Inspect shutter assembly

(1) for physical damage. Check for debris within assembly. Check for smooth operation of shutters when

moved manually. Check for chipped paint or rusting.

(2) Bracket Assembly. Inspect that brackets (2)

are securely mounted to shutters (3). Check that

bracket bearings are not excessively worn. Refer to

Operator and Organizational Maintenance

Manual

(3) Shutters. Inspect shutters (3) for physical

damage and secure mounting to brackets (2).

(4) Air Housing Panel and Door. Inspect air housing panel and door (5) for physical damage.

(5) Grille. Inspect grille (6) for secure mounting

to blower housing (7). Check for physical damage.

 (For units without ASK.)

(6) Blower Housing. Inspect blower housing (7)

for physical damage. Check that blower housing is

securely mounted to engine.

b. Removal. Refer to Operator and Organizational Maintenance

Manual.

c. Disassemble. Disassemble repairable components of the cooling system per Operator and

Organizational Maintenance Manual.

Solvent, Dry Cleaning P-D-680, Type II is

flammable and moderately toxic to skin, eyes

and respiratory tract. Eye and skin protection required. Good general ventilation is

d. Repair.

(1) Shutter Assembly. Refer to Operator and

Organizational Maintenance Manual to remove and

replace defective components. Repair physical damage

by removing the dents, welding breaks in shutter assembly box. Clean repaired area with dry cleaning

solvent Federal Specification P-D-680. Paint as required with MIL-T-704, type A, semigloss, olive drab,

color no. 24087.

(2) Bracket Assemblies. Replace bracket (2) or

bearings if required.

(3) Shutters. Bump out dents and straighten shutters (3) if required. Clean with dry cleaning solvent

and repaint if necessary.

(4) Air Housing Panel and Door. Clean air housing panel and door (5) with dry cleaning solvent and

repaint if necessary.

(5) Grille. Straighten any bent wires on grille

(6) or weld if required to repair. (For units without ASK.) 

(6) Blower, Housing. Bump out dents in blower

housing (7), repair cracks with welds if necessary

and clean with dry cleaning solvent. Paint as required.

e. Installation. Install engine cooling system. On ASK equipped

generators, install cover and exhaust plenum assemblies per

Operator and Organizational Maintenance Manual.

3-3. HIGH TEMPERATURE CUTOUT SWITCH.

a. Remove (see figure 3-1). On ASK equipped generators,

refer to Operator and Organizational Maintenance Manual and

remove top panel assembly and exhaust plenum.

(1) Disconnect electrical leads (10).

(2) Straighten locking tab (12) and remove switch

normally adequate. (11).

Change 6 3 - 1
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 3-1. Engine Cooling System

3-2
The high temperature cutout switch must be

removed and tested semiannually (500 hours).

b. Test.

(1) Using an oil pot tester and peanut oil, heat

Oil to 394° ± 10oF (201° ± 5°C).

(2) Immerse threads and bottom surface of switch

in oil. After a minimum of 1 minute, use an ohmmeter and check continuity between terminals on

switch.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(3) If continuity exists, replace with a new switch.

(4) Keep threads and bottom surface of switch in

oil and allow it to cool to 300o F (149 o C) minimum.

Repeat continuity check in (2) above.

(5) If continuity does not exist, replace with a

new switch.

c. Installation.

(1) Install switch (11) on engine and lock with

locking tab (12).

(2) Connect electrical leads (10) to switch terminals.

(3) On ASK equipped generators, refer to Operator and

Organizational Maintenance Manual and replace top panel assembly

and exhaust plenum.

Change 6 3-3/(3-4 blank)

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 4

MAINTENANCE OF FUEL SYSTEM

Section I. DESCRIPTION AND FUNCTION

4-1. GENERAL.

The engine fuel system consists of two pressure system; the

low pressure system and the high pressure system. In the low

pressure system, a fuel pump may draw fuel from an external

source to till set tank or set tank may be filled manually. If an

external fuel source is selected, a float valve assembly in the

set tank maintains the fuel level in the tank. Two other fuel

pumps (in series) draw fuel from the set tank and force the

fuel through a primary strainer, two secondary filters, and a

check valve assembly, to the injection pump. In the high

pressure system, the fuel injection pump forces the fuel,

under high pressure, to the fuel injection nozzles. The injection nozzles provide fuel to each combustion chamber of the

engine. A small quantity of unused fuel is returned from the

injectors and injector pump to the fuel tank. A cam and gear

on the camshaft drives the fuel injection pump. The gear

drives the pump face gear, providing fuel distribution to

each cylinder in the proper order. The cam operates the

pump plunger, pressurizing fuel to the nozzles. A control

sleeve meters fuel by controlling the length of time the

plunger spill port is closed, maintaining pressure, and therefore, the amount of fuel delivered in each stroke. The pintle

type injection nozzles are conventional inward opening with

adjustable opening pressure. They are factory adjusted to

open at 1900 to 1950 psi.

Section II. MAINTENANCE OF FUEL TANK

4-2. FUEL TANK.

a. Inspect. On ASK equipped generators, refer to

Operator and Organizational Maintenance Manual and

remove left panel and side closure assemblies. Inspect the

fuel tank per Operator and Organizational Maintenance

Manual.

b. Remove. Remove fuel tank and remove components per Operator and Organizational Maintenance Manual.

c. Test. Plug all but one opening in the fuel tank. Connect a regulated low pressure air supply to tank opening.

Apply 3/4 to 1-1/4 psi to tank and submerge tank into water.

Check for leaks.

d. Repair.

WARNINGS

Observe all safety precautions when soldering

fuel tank. Avoid breathing fumes generated by

lead soldering. Eye protection is required.

Hot refueling of generators while they are operating poses a safety hazard and should not be

attempted. Hot engine surfaces and sparks produced from the engine and generator circuitry

are possible sources of ignition. Severe injury,

death and/or damage to the equipment may

result.

(1) Repair leaks in fuel tank by soldering,

(2) Clean repaired area with dry cleaning solvent

Federal Specification P-D- 680.

(3) Paint as required with MIL-T-704, type A,

semigloss, olive drab, color no. 24087.

e. Install.

(1) On ASK equipped generators, refer to Operator and Organizational Maintenance Manual and install left

panel and side closure assemblies. Install the fuel tank and

components per Operator and Organizational Maintenance

Manual.

(2) Fill tank with fuel oil.

Change 7 4-1/(4-2 blank)

TM5-6115–585–34

NAVFAC P-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

CHAPTER 5

MAINTENANCE OF STARTING

Section I. DESCRIPTION AND

5-1. GENERAL

SYSTEM

FUNCTION

The engine is cranked by a 24 volt electric starter.

when the starter motor solenoid is energized, the

solenoid core pulls in, shifting the pinion gear

into engagement with the engine flywheel ring gear.

The starting motor is protected from overspeeding

by an overrunning clutch. At the same time, contacts in the solenoid close to provide a circuit

for the starter. Two 12 volt batteries in series

are used. The starting switch for this starting

circuit is located in the control cubicle.

Refer to the Operator and Organizational Maintenance Manual. for starting and operating the set. A

blower wheel alternator is utilized to recharge

the batteries.

a. A new(Style II) gear-reduction electric

starter will be installed on engines manufactured

during 1990; and will be available as a replacement

when the original starter, (Style I) is no longer

available. The Style II starter are interchangeable with the Style I starter.

Section II. MAINTENANCE

5-2.

a.

STARTER ASSEMBLY

Test on Equipment. Refer to the Operator and

organizational Maintenance Manual.

b. Renuval. Refer to the Operator and Organizational Maintenance Manual.

c. Disassembly; Style I (see figure 5-1)

(1) Remove nut (1) and lockwasher (2) from

solenoid (13). Remove nut (3) and lockwasher (4)

from brush assembly (21) terminal. Tag and remove

lead (5).Remove nut (6) and lockwasher (7) from

lower solenoid terminal, and loosen field coil

connector (8).

(2) Remove cutter pin (9) and pin (10) from

yoke (32). Remove screws (ll),lockwasher (12)

and remove solenoid switch (13).

(3) Remove through bolts (14), lockwasher

(15) and remove back plate assembly (16) and

thrust washer (27). Remove nut (17) and lockwasher

(18) from brush assembly (21) terminal. Lift brush

springs (20) and remove brush assembly (21).

the insulating washer set (19) from brush

assembly (21). With brush spring raised, remove

other brushes (26) from brush holder (24). Remove

screws (22), lockwashers (23) and remove brush

holder (24).

(4) Remove retainer (29), boot (30), pin (31)

and separate pinion housing (28) and frame assembly (25). Do not lose thrust washer (27).

(5) Remove yoke (32) ad remove armature (33)

and drive assemblv (35). Remove lock ring and stop

(34) by forcing stop toward armature until lock

ring becomes accessable. See figure 5-3. Remove

lock ring and stop(34), and drive assembly (35)

from armature (33). Do not disassemble drive

assembly.

(6) Remove bearing (36) by pressing from

pinion housing (28).

d.Disassembly; Style II (see figure 5-2)

(1) Remove nut (1) and lockwasher (2) from

Solenoid (5). Move lead terminal off solenoid

and swing it aside. Install nut and lockwasher

on solenoid threaded terminal for safe-keeping.

(2) Remove screws (3), spacer(s) (4) and

remove solenoid (5) from front bracket.

NOTE

Solenoid mounting screw removal may require the use of a impact type driver.

(3) Remove nuts (6), flat washers (7) and

remove ground terminal bracket assembly (8).

NOTE

Disassembly of ground terminal bracket

assembly not required unless the terminal

threads have been damaged. Refer to the

repair parts manual for terminal components.

Change 8 5-1
Figure 5-1.

5-2 Change 8
Figure 5-2.

Change 8 5-3
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

(4) Remove the through studs (9), remove

screws (10) and rear cover (11).

(5) Raise the brush springs (12) lift the

brushes (13) and remove brush holder (14).

(6) Remove stator (frame assembly) (15), rear

bearing (16), armature (17) and armature front

bearing (18).

(7) Remove screws (19), cover (20), retaining

ring (21), flat washer (22) and spacer (23).

(8) Remove screw (24) freeing the center

bracket (25).

NOTE

There is a spring force behind screw (24).

(9) Remove and count the flat washers (26),

remove packing (27), outer spring (28), inner

spring (29).

NOTE

Note the direction in which

installed before removal.

(10) Remove lever (30) and

the lever is

gear (31).

(11) push stopper (33) towards front bracket

to release retaining ring (32). See figure 5-3.

Remove retaining ring (32), stopper (33), pinion

gear (34) and spring (35).

(12) Remove over running clutch (36) from

the front bracket assembly (37).

e. Cleaning inspection

(1) Cleaning. Clean dust off parts with

compressed air or soft brush. Remove grease and

oil with dry cleaning solvent.

Do not clean the armature or field coils

with solvent as wire insulation may be

damaged. Do not dip drive assembly or

overrunning clutch in solvent as they

are packed in grease and cannot be repacked. May result in premature failure.

NOTE

Pinion shaft of the overrunning clutch

must turn freely in a clockwise direction

and lock up when turned counter-clockwise.

(2) Remove discoloration or oxidation from

commutator with fine sand paper grade 00 or 000.

Clean off sand with compressed air. Use only sandpaper!

(3) Bearings. Inspect all bearings for wear

or damage. Replace if excessively worn or damage,

or replace back plate assembly, pinion housing,or

front bracket assembly if individual bearing is

not available.

(4) Drive Assembly. Style I Starter only.

Refer to Operator and Organizational Maintenance

Manual.

(5) Brushes. Refer to Operator and

Organizational Maintenance Manual.

(6) Solenoid Switch. Refer to Operator and

Organizational Maintenance Manual.

(7) Armature. Inspect armture for wear.

Inspect commutator for wear or runout. See test

proceedure for runout. If commutator wear or

runout is not excessive, resurface according to

the repair proceedures. Replace armature if it

is excessively worn or damaged.

(8)Yoke/Lever. Inspect for damage or wear,

replace if worn or damage.

(9) Frame Assembly. Inspect frame assenbly

for damage. Check wires of field coil for buring

or worn insulation. Check pole shoes for tightness. Check field coils for signs of armature

contact which may indicate bad bearings. Repair

or replace if damage or defective.

f. Test Bench

(1) Testing Starter. Refer to Operator and

Organization Maintenance Manual.

Figure 5-3. Pinion Gear Stopper Removal

5-4 Change 8
Figure 5-4. Testing Armature for Grounds

(2) Testing Armature.

(a) Testing Armature for grounds. Touch

armature shaft and the end of each commutator bar

with a pair of ohmmeter leads. There should be no

continuity. If continuity is indicated between

any commutator bar and armature shaft, it indicates a grounded armature. Replace grounded armature. See figure 5-4.

(b) Testing Armature for shorted Coils.

A growler is necessary to test for shorted coils.

With the armature in the growler, turn the

growler on and hold a thin steel strip parrallel

over the armature surface. Turn growler on, and

if the steel strip vibrates or is attracted to the

armature surface, the armature is shorted or

grounded. Turn off growler, rotate armature onequater turn and repeat test. DO this for one

complete revolution of armature. See figure 5-5.

If armature has a short or is grounded, replace

it.

(c) Testing Armature for Open Coils.

Test coils for continuity with ohmmeter. Place one

lead on commutator bar, other lead on the next bar.

If there is

the reading

If armature

discontinuity (infinite resistance),

indicates open coil. See figure 5-6.

has an open coil, replace it.

TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

Figure 5-5. Testing Armature for Shorted Coils

Figure 5-6 Testing Armature for Open Coils

Change 8 5-5
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

(d) Testing Commutator Runout. Place the (e) Testing Armature Shaft Runout.

armture in a test bench and check runout with a Place armature in a test bench and check shaft

dial indicator. See figure 5-7. When commutator runout with a dial indicator. Runout should not

runout exceeds 0.004 inch, commutator should be exceed 0.006 inch. See figure 5-8. If shaft is

refaced. After refacing commutator, check that it bent or worn, armature must be replaced.

meets minimum specifications. Check and if

necessary, undercut mica as given under repair.

Figure 5-7. Checking cummutator Runout

Figure 5-8. Checking Armature Shaft Runout

5-6 Change 8
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

(3) Testing Field Coils. See Operator and

Organizational Maintenance Manual.

(4) Testing Brushes. See Operator and

Organizational Maintenance Manual.

(5) Testing Brush Springs. Style I Starter.

(see figure 5-9).

Measure brush spring with tension meter. Push the

brush and take reading just as the brush projects

a little from the brush holder. On a new brush,

the spring tension should be 32 to 40 ounces. If

brush spring tension is below 20 ounces, replace

it.

Figure 5-9. Testing Brush Spring Tension

STYLE I Starter Only.

(6) Testing Brush Springs. Style II Starter.

Firmly hold brush holder and push the brush

against the brush spring until completely inside

of its guide. If little or no resistance (tension)

is present, spring should be replaced. Badly worn

or pitted brush surface may indicate weak spring.

(7) Testing Solenoid Switch. Style I Starter.

(see figure 5-10).

(a) Check to be sure plunger moves

freely in coil. Measure pull-in coil current using

a ammeter. See Test A, figure 5-10, Current should

not exceed 16 amps.

(b) Measure the hold-in current using

Test B, figure 5-10. Current should not exceed

amps.

(c) Check total hold and pull current

draw using Test C, figure 5-10. Total current

6

should not exceed 25 amps. Replace defective solenoid switch.

(8) Testing Solenoid Switch. Style II Starter.

(see figure 5-10).

(a) With solenoid on starter, push the

solenoid plunger in and release it. The plunger

should return to its original position. Plunger

should slide in and out freely when push by hand.

(b) Check for continuity between terminal

“B" and terminal “M” with an ohmmeter. There

should be no continuity.

(c) Push the plunger in and hold while

checking continuity between termiml “B” and “M”.

The ohmmeter should read zero ohm with complete

continuity. If no continuity reading, the solenoid

is defective, replace it.

g. Repair

(1) Repairing Starter. Repair starter by

replacing defective components. Repair procedures

for individual components are as follows:

(2) Repairing Armature. If the commutator

wear or runout is not excessive, (max 0.004), it

may be resurfaced as follows:

(a) Resurfacing Commutator. Place the

armature in a lathe. Style I starters may be

turn down with a cutting tool. Style II starters

my Not be turn down with a cutting tool! Only

00 or 000 sandpaper may be used on Style II and

if wear or runout cannot be corrected, the Style

II armture must be replaced! The Style I

commutator turn down may not reduce the diameter

of commutator below 1-1/16 inches.

(b) Undercutting Mica. After cummutator

is resurfaced, undercut mica to a depth of 0.025

to 0.032 inch using a power driven undercutting

tool. If no power driven tool is available, the

mica may be under cut by hand. See figure

5-11.

NOTE

Use care in undercutting.Do not widen

commutator slots by removing metal from

bars, and do not leave a thin edge of mica

next to bars. Figure 5-11 illustrates good

and bad exa of undercutting. After

mica has been undercut, polish commutator

in a lathe with number 00 to 000 sandpaper

while the armature is rotating. Remove all

copper sand and mica with compressed air.

Change 8 5-7
TM5-6115-585-3 4

NAVFACP-8-623-3 4

TO-35C2-455- 2

TM-05684C/05685B-3 4

Figure 5-10. Testing Solenoid Switch

5 - 8 Change 8
h. Reassembly Style I Starter (see figure 5-1)

(1) Soak sleeve bearing (36) in SAE 10 oil

for 15 minutes before assembly of stater.

(2) Press bearing (36) into pinion housing

(28).

(3) Slide drive assembly (35) onto the

armature shaft. Slide stop and position lock ring

(34) in its groove on the armarure shaft. Pull

step over lock ring. A bearing puller tool may

be required.

(4) Install thrust washer (27) on the end

of the armature shaft. Slip yoke (32) onto the

drive assembly (35) and install both in pinion

housing (28). Install pin (31) in pinion housing

to hold yoke (32) in place.

(5) When brushes (26) are excessively worn,

cut each brush lead 1 inch fron the welded connection (see figure 5-12). Install new brush as

follows:

(a) Using rosin core solder and a soldering iron, or heavy duty soldering gun, tin the

remaining sections of the original brush lead.

(b) Position the new brush lead next to

the tinned section of the original brush lead.

Install and crimp the brass strip connectors (that

are supplied with new brush) around both leads to

hold the brush in place. See figure 5-12.

(c) Solder the new brushes in place.

Position the brush leads so they do not contact

the frame or interfere with the thru bolt

installation.

(6) Install brush assembly (21) and brush

washer set (19) in frame assembly (25). Install

the previously removed nut (17) and washer (18)

onto the stud of the brush assembly (21). See

figure 5-1.

(7) Install brushes (21 and 26) in brush

holder (24). Attach brush holder to frame

assembly (25) with screws (22) and lockwashers

(23).

(8) Assemble armature (33), drive assembly

(35) and pinion housing (28) with frame assembly

(25).

(9) Install brush springs (20).

(10) Install thrust washers (27) on the end

of the armture shaft (33) and install back plate

assembly (16) on frame assembly (25) with the

thru bolts (14) and lock washers (15).

TM 5-6115–585-34

NAVFAC P-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

(11) Install solenoid (13) on frame assembly

(25) with screws (11) and lockwashers (12) so the

bottom terminal of solenoid goes thru the field

coil connector (8). Attach terminal to connector

with nut (6) and lockwasher (7). Connect plunger

of solenoid to yoke (32) with pin (10). Secure

pin (10) with cotter pin (9). Install boot (30)

and boot retainer (29) over the yoke (32).

(12) Connect tagged lead (5) between

solenoid switch (13) and brush assembly (21)

threaded terminal using nut(1), nut (3) and lockwashers (2), lockwasher (4). Remove tags.

i. Reassmbly Style II Starter (see figure 5-2).

(1) Apply a light coating of grease to the

following components before assembling starter.

Armature shaft splines

Reduction Gear teeth

Sell Bearings

Over-running Clutch shefts

Pinion Gear teeth

Lever sliding pads

Stopper for pinion gear

Front Bracket sleeve bearing

Solenoid plunger

(2) Place Reduction gear (31) and flat

washers (26) onto rear shaft of over-running

clutch (36). Insert shaft with gear and washers

thru Center bracket (25).

(3) Install spacer(23), flat washer (22) and

retaining ring (21) on over-running clutch shaft.

(4) Push the over-running clutch (36) towards

the center bracket and measure the end play between the center bracket (25) and the flat washer

(22).

(5) Adjust end play to between 0.0039 to

0.020 inch (0.1 to 0.5 mm) with adjustment washers

(26).

(6) Install cover (20) with screws (19).

(7) Install lever (30) on to over-running

clutch, check for correct positioning as was

referrred in disassembly. Add inner spring (29),

outer spring (28) and packing (27). Slide clutch

shaft thru front bracket assembly (37) and secure

center bracket to front bracket with screw (24).

Front and center brackets are under spring

tension, care must be used to keep packing

and inner/outer spring in place while tighting the screw.

Change 8 5-9
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

Figure 5-11. Undercutting Mica

Figure 5-12. Brush Replacement STYLE I Starter Only

5-10 Change 8
(8) Slide spring (35), pinion gear(34) and

Stopper (33) onto shaft. Position retaininq ring

(32) in groove on shaft and pull stopper over

ring to secure it. A bearing puller tool may

be required.

(9) Place bearings (16) and (18) on the

armature shaft, and insert armature into the

center bracket. Slide Stator (15) over armature

and into center bracket. Align stator to bracket

by fitting tab on stator into notch on center

bracket.

(10) Place brush holder (14) with brush

springs (12) in place, over the communtator of

the armature. Lift each brush spring (12) and

insert brush (13) into the guide on the brush

holder (14).

(11) Place rear cover (11) over brush holder

and against stator (15). Rotate slighly and align

threaded holes in brush holder with holes in

cover. Secure brush holder to cover with screws

(10).

(12) Pass thru studs (9) through rear cover

(11) into tappd holes in front bracket assembly

(37) and secure.

(13) Place washers (7) on thru studs, place

terminal bracket assembly (8) on studs and add

nuts (6).

(14) Place spacers (4) on solenoid switch (5)

and align solenoid plunger slot over lever (30).

Secure solenoid and spacers to front bracket

assembly (37) with screws (3).

(15) Install field coil lead from stator (15)

onto lower threaded terminal of the solenoid (5).

Secure with nut (1) and washer (2).

J. Test after Repair/Overhaul. Style I Starter

(1) After the starter is assembled, check

the armature end play by inserting thickness

gauge between thrust washer (27) and pinion

housing (28). See figure 5-1. It should be betwen 0.005 and 0.035 inch. Adjust end play by

adding or removing thrust washers (27) on the

commutator end of the Armature.

(2) Check pinion gear clearance. See figure

5-13. Proper clearance is important to insure

starter engagement. To check, press on solenoid

plunger to shift pinion gear into full mesh position. While holding plunger in, measure clearance

with feeler gauge (4) between pinion gear and

step. The proper clearance is 0.096 +0.030/-0.020

inch. Adjust clearance by turning solenoid plunger

link (1) in to decrease gap, or out to increase

the gap. See figure 5-13 cutaway view. Reinstall

the pin (2) and cotter pin (3) securing plunger

link (1) to yoke.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

Figure 5-13 Checking Pinion Clearance

STYLE I Starter

K. Test after Repair/Overhaul. Style II Starter.

(1) After starter is assembled, check the

pinion gear travel to ensure proper starter engagement. See figure 5-14.

(a) To measure, provide as 24 volt DC power

source, such as battery. Connect the positive“+”

battery to the solenoid terminal (S) with a

electrical lead that includes a momentary switch.

(b) Connect the negative “-” battery terminal to the ground terminal (G), with electrical

lead.

(c) Remove nut and lockwasher from terminal

(M), than remove and secure lead (L) away from the

solenoid.

(d) Close and hold the momentary switch to

apply power to terminal (S) forcing the solenoid

plunger to pull the lever and move the pinion gear

forward. Measure the distance between mounting

surface of starter front bracket and outer edge of

pinion gear to determine the maximum travel(X).

Release the power source and the internal springs

will move lever to original position, returning

the pinion gear to its at rest position. Measure

this distance (Y). The difference between measurement (X) and (Y) should fall within the nominal

travel distance (Z) of 17mm + or - lmm.

Change 8 5-11
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-455-2

TM-05684C/05685B-34

Figure 5-14. Checking Pinion Travel STYLE II Starter

(e) If adjustment of pinion gear travel L. Installation. Refer to Operator and

is required, remove screws (1) lift off solenoid Organization Maintenance Manual:

(3). Adjust pinion travel by adding or removing

mounting spacers (2). Increasing the number of

washers will decrease maximum travel distance;

and removing washers will increase maximum travel

distance.

NOTE

Solenoid mounting scerw removal may require the use of a impact type driver.

(f) Reinstall the solenoid (3) make sure

plunger engages the lever. Position the spacers

(2) and install new screw (1) if necessary.

(g) Repeat steps (a) thru (e) until pinion

travel is acceptable.

(h). Remove power source and install lead

(L) on terminal (M). secure with nut and washer.

5-12 Change 8
6-1. DC CONTROL SYSTEM.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34 

CHAPTER 6

MAINTENANCE OF CONTROL SYSTEM

Section I. DESCRIPTION AND FUNCTION

Refer to the Operator and Organizationa l

Maintsnance Manual for the description and function

of the dc control system.

6-2. AC INSTRUMENTATION SYSTEM.

Refer to the Operator and Organizationa l

Maintenance Manual for description and function of

the ac instrumentation system.

Section II.

6-4. CONTROL CUBICLE.

a. Wiring Harness.

(1) Remove. Disconnect wires of wiring harness

from all components. Remove clamp attaching harness

to control panel and remove harness.

(2) Repair. Table 6-1 lists the wire number,

gauge, color, length and terminal lugs for each wire

in the harness. Repair consists of replacing wires as

required.

(3) Installation. Install harness by connecting

wires to components per figure 6-1. Attach harness to

control panel with clamp.

b. Meters (on equipment test).

(1) Frequency Meter (M3) (16, figure 6-3). Connect a frequency meter of known accuracy to single

phase output terminals of load terminal board. Make

certain reconnection switch is in proper position for

single phase output. Operate Generator Set and check

readings of panel meter (M3) against test frequency

meter. If panel meter does not give the same reading

as the test meter, test transducer as given in (2) below.

(2) Frequency Transducer (A3) (56, figure 6-3).

Test transducer using the same procedure as for

testing frequency meter. If transducer does not give

proper meter reading, replace the transducer and/or

the meter.

6-3. VOLTAGE REGULATOR.

Excitation current is controlled through the static

type automatic voltage regulator. The voltage regulator continuously compares the output voltage of the

synchronous generator with a stable reference voltage. The difference between the two voltages constitutes an error signal which indicates an output

voltage that is higher or lower than the generator

set point. This error signal is amplified and used to

control the direct current output of the voltage regulator which is applied to the control windings of the

current-voltage transformers.

MAINTENANCE

(3) Percent Current Meter (M4) (17, figure 6-3).

Connect an ac test ammeter in series with the % rated

current meter. Operate Generator Set with a single

phase load. Continue adding load to set until meter

reads 0.75 amps. Meter (M4) should read 100% ±2%.

Replace meter if necessary.

(4) AC Voltmeter (M5) (18, figure 6-3). Attach

test ac voltmeter in parallel (across terminals) with

panel ac voltmeter (M5). Operate Generator Set and

compare readings of the two meters. Panel voltmeter

must be accurate to ± 2.5%, except between 115 and

125 volts, accuracy must be ± 3 volts and between

200 and 250 volts, accuracy must be ± 5 volts. If panel

meter does not meet these requirements, replace

meter.

c. Meters (remove).

(1) Frequency Meter (M3) (16, figure 6-3). Tag

and disconnect two leads from meter. Remove three

screws, lockwashers, and nuts attaching meter to

panel and remove meter.

(2) Frequency Transducer (A3) (56, figure 6-3).

Tag and disconnect four leads to frequency transducer.

Remove four screws (54) and nuts (55) attaching

transducer to back of control cubicle and remove

transducer.

(3) Percent Current Meter (M4) (17, figure 6-3).

Tag and disconnect two leads from meter. Remove

three screws, lockwashers, and nuts attaching meter

to control panel and remove meter.

Change 4 6-1
TM-5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-056684C/05685B-34

Figure 6-1. Control Cubicle Wiring Harness

6 - 2 Change
Wire No.

D24A16

D25A16

D26A16

D26B16

D27A16

D74A16

D75A16

H52A12

H52B12

H52H12

K51A12

L56A16

L56B16

L56C16

P50B10

P50C12

P50D12

P50E16

P50F16

P53A16

P53B16

P53C16

P53D16

P54A16

P55C10

P55D16

P55G16

P55H16

P55J16

P55L16

P55N16

P55P16

P55R16

P55U16

P57A16

P57B16

P57C16

P58A16

P59C16

P60A16

P60B16

P60C16

P61A16

P61B16

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C-34

Table 6-1. Control Cubicle Wiring Harness

NOTE

All wires are copper, 600V, per MIL-W-5086/2.

Gauge

16

16

16

16

16

16

16

12

12

12

12

16

16

16

10

12

12

16

16

16

16

16

16

16

10

16

16

16

16

16

16

16

16

16

16

16

16

16

16

16

16

16

16

16

Marking

Color

black

black

black

black

black

black

black

red

red

red

red

red

red

red

red

red

red

red

red

red

red

r e d

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

red

* Onan Division of

Length

in Inches

13

13

10

24

10.5

31.5

32

9.5

18

18

21

39

38.5

42

11.5

20

9

41

15.5

46.5

37

46

44

42

15

18

19

42

44

16.5

40

13

16.5

24

38.5

17

17

27

22

11.5

36

19.5

39.5

10

Onan Corporation (44940)

Terminal Find No.

Terminal Lugs

MS25036-154, MS25036-107

MS25036-154, MS25036-107

MS25036-154, MS25036-107

MS25036-107

MS25036-154, MS25036-107

MS25036-154, MS25036-107

MS25036-154, MS25036-107

MS25036-112, 332-1819*

332-1819*

332-1819*

MS25036-112

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

332-1819*

MS25036-112, 332-1819*

MS25036-112, 332-1819*

MS25036-153, MS25036-107

MS25036-107

MS25036-153, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

332-1819*

MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107, MS25036-107

MS25036-107, MS25036-107

Change 1 6-3
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C-34

Table 6-1. Control Cubicle Wiring Harness (Cont)

Marking Length Terminal Find No.

Wire No. Gauge Color in Inches Terminal Lugs

P61C16 16 red 19.5 MS25036-107

P61E16 16 red 19.5 MS25036-107

P62A16 16 red 42 MS25036-107, MS25036-107

P62B16 16 red 19.5 MS25036-107

P62D16 16 red 19.5

P64A16

MS25036-107

16 red 9.5 MS25036-107, MS25036-107

P64B16 16 red 41 MS25036-107, MS25036-107

P64C16 16 red 21.5 MS25036-107

P64E16 16 red 21 MS25036-107, 323-0705*

P66C16 16 red 43 MS25036-107

P66D16 16 red 12 MS25036-107, MS25036-107

P66E16 16 red 21 MS25036-107, MS25036-107

P66F16 16 red 15 MS25036-107

P67E16 16 red 30.5 MS25036-107

P67F16 16 red 12 MS25036-107, MS25036-107

P67G16 16 red 42 MS25036-153, MS25036-107

X9G16 16 black 23 MS25036-107

X9H16 16 black 19 MS25036-107, MS25036-107

X9Jl6 16 black 16 MS25036-153, MS25036-107

X9Kl6 16 black 21 MS25036-153, MS25036-107

X12G16 16 black 23 MS25036-107

X12H16 16 black 19 MS25036-107, MS25036-107

X12J16 16 black 16 MS25036-153, MS25036-107

X12K16 16 black 22 MS25036-153, MS25036-107

X14D16 16 black 24 MS25036-107

X15D16 16 black 22.5 MS25036-107

X17D16 16 black 23 MS25036-107

X17E16 16 black 42 MS25036-107, MS25036-107

X17F16 16 black 45 MS25036-107, MS25036-107

X22C16 16 black 23 MS25036-107

X23C16 16 black 22 MS25036-107

X29C16 16 black 25 MS25036-107

X31D16 16 black 25.5 MS25036-107

X34C16 16 black 19 MS25036-107

X34D16 16 black 40.5 MS25036-107, MS25036-107

X34E16 16 black 44.5 MS25036-107, MS25036-107

X35C16 16 black

X39C16

25 MS25036-107

16 black 27 MS25036-107

X40C16 16 black 28.5 MS25036-107

X41A16 16 black 54.5 MS25036-153, MS25036-107

X42A16 16 black 54 MS25036-153, MS25036-107

X43A16 16 black 37 MS25036-153, MS25036-107

X44A16 16 black 35 MS25036-153, MS25036-107

X45A16 16 black 25 MS25036-153, MS25036-107

X46A16 16 black 26.5 MS25036-153, MS25036-107

* Onan Division of Onan Corporation (44940)

6-4 Change 1
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C-34

Table 6-2. 10KW Generator Set Wiring Harness

NOTE

All wires are copper, 600V, per MIL-W-5086/2.

Marking Length

Wire No. Gauge Color in Inches Terminal Lugs

D26C16 16 black 31

H52C12 12 red 53

H52J12 12 red 53

K51B12 12 red 35 MS25036-112

P50A10 10 red 39

P50G16

MS25036-113

16 red 53

P55B10 10 red 36 MS25036-113

P55E16 16 red 31

P55M16 16 red 35

P55S16 16 red 55

P58B16 16 red 47

P59B16 16 red 47

P60D16 16 red

P61D16

31

16 red 20

P61F16 16 red 20.5

P62C16 16 red 26

P62E16 16 red 20

P63A16 16 red 49

P64D16 16 red 49 MS25036-153

P65A16 16 red 38 MS25036-153

P66B16 16

P66G16

red 26.5

16

P67D16

red 53

16 red 31

X9F16 16 black 31

X12F16 16 black 31

X14C16 16 black 31

X15C16 16 black 31

X17C16 16 black 31

X22B16 16 black 31

X23B16 16 black 31

X29B16 16 black 31

X31C16 16 black 31

X34B16 16 black 31

X35B16 16 black 31

X39B16 16 black 31

X40B16 16 black 31

Change 1 6-5
TM5-6115-585-3 4

NAVFAC P-8-262-12

TO-35C2-3-455- 2

TM-05684C-3 4

Figure 6-2. Generator Set Wiring Harness

6-6
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 6-3. AC Output Control Box Wiring Harness (MEP-003A Only)

NOTE

All wires are copper, 600V, per MIL-W-5086/2.

Marking Length

Wire No. Gauge Color in Inches Terminal Lugs

D26D16 16 black 21 MS25036-107

D26E16 16 black 17 MS25036-107, MS25036-108

D26F16 16 black 17 MS25036-107, MS25036-108

D26G16 16 black 32 MS25036-107, MS25036-153

D26H16 16 black 15 MS25036-107, MS25036-108

D26J16 16 black 3.5 MS25036-107

D26K16 16 black 34 MS25036-107, MS25036-153

P55F16 16 red 24 MS25036-107

P60E16 16 red 22 MS26036-107

P60F16 16 red 19 MS25036-107, MS25036-107

P60G16 16 red 20 MS25036-107

P67A16 16 red 19 MS25036-107, MS25036-107

P67B16 16 red 20 MS25036-107

P67C16 16 red 22 MS25036-107

X1A8 8 black MS25036-115

X2A8 8 black MS25036-115

X3A8 8 black MS25036-115

X3B12 12 black 30 MS25036-112, MS25036-156

X4A8 8 black 16 MS25036-115

X5A8 8 16.5 MS25036-115

X6A8 8 black 15 MS25036-115

X6B12 12 black 32 MS25036-112, MS25036-156

X7A8 8 black MS25036-115

X7B8 8 black 12 MS25036-115, MS25036-115

X7D16 16 black 13.5 MS25036-108, MS25036-153

X8A8 8 black MS25036-115

X8B8 8 black 18 MS25036-115, MS25036-115

X8D16 16 black 19 MS25036-108, MS25036-153

X9A8 8 black MS25036-115

X9B8 8 black 10 MS25036-115, MS25036-115

X9D16 16 black 17.5 MS25036-108, MS25036-153

X9E16 16 black 17 MS25036-108

X11A8 8 black 19 MS25036-115

X11B8 8 black 15 MS25036-115, MS25036-115

X11B16 16 black 35 MS25036-153, MS25036-108

X12A8 8 black 20 MS25036-115

X12B8 8 black 19 MS25036-115, MS25036-115

X12D16 16 black 35 MS25036-153, MS25036-108

X12E16 16 black 21 MS25036-108

X13B8 8 black 17 MS25036-115

X14B16 16 black 22 MS25036-108

X15B16 16 black 22.5 MS25036-108

X17B16 16 black 20 MS25036-108

X21A12 12 black 10 MS25036-156, MS25036-156

X22A16 16 black 20 MS25036-153

X23A16 16 black 15.5 MS25036-153

X28A16 16 black 14 MS25036-153, MS25036-153

Change 5 6-7
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 6-3. AC Output Control BOX Wiring Harness (MEP-003A Only) (Cont)

Marking Length

Wire No. Gauge Color in Inches Terminal Lugs

X29A16 16 black 19.5 MS25036-153

X30A16 16 black 14 MS25036-153, MS25036-107

X30B16 16 black 15 MS25036-107, MS25036-108

X30C16 16 black 32 MS25036-153, MS25036-107

X31A16 16 black 7 MS25036-107, MS25036-153

X31B16 16 black 22 MS25036-107

X32A16 16 black 16 MS25036-153, MS25036-108

X33A16 16 black 14.5 MS25036-153, MS25036-153

X34A16 16 black 17 MS25036-153

X34A16 16 black

X36A16

19 MS25036-153

16 black 28

X37A16 16

MS25036-153, MS25036-153

black 28 MS25036-153, MS25036-153

X38A16 16 black 25 MS25036-153, MS25036-153

X39A16 16 black 26 MS25036-153

X40A16 16 black 21 MS25036-153

X47A16 16 black 22 MS25036-107, MS25036-153

X48A16 16 black 20.5 MS25036-107, MS25036-153

X49A16 16 black 16 MS25036-107, MS25036-153

X76A16 16 black 16 MS25036-153, MS25036-108

X77A16 16 black 34 MS25036-153

X31F16 16 black 35 MS25036-107, MS25036-153

(4) AC Voltmeter(M5) (18, figure 8-3). Tag and disconnact 6-6. VOLTAGE REGULATOR.

two leads from meter. Remove three screws, nuts, and lockwashers attaching meter to control panel and remove meter. a. Test, on Equipment.

d. Meters (replace) (1) Operate set at rated load and adjust output

(1) Frequency Meter(M3) (16, figure 6-3). Position meter voltage as follows:

in control panel and attach with three screws, Iockwashers, and (a) Refer to figure 6-5 (or 6-5.1) and turn

nuts. Connect the two electrical leads and remove tags. adjustment screw on resistor R15 (or R16) counter-

(2) Frequency Transducer (A3) (56, figure 6-3). Position

clockwise until voltage becomes unstable.

transducer to back of control cubicle and attach with four screws

(54) and nuts (55). Connect the four electrical Ieads and remove

tags

(3) Percent Current Meter (M4) (17, figure 6-3). Position

meter on control panel and attach with three screws, Iockwashers

and nuts. Attach the two electrical leads and remove tags.

NOTE

Voltage instability will be most evident immediately following application or removal of

the load.

(b) Turn screw on R15 (or R16) clockwise

(4) AC Voltmeter (M5) (18, figure 6-3). Position meter on

control panel and attach with three screws, Iockwashers, and nuts.

Attach the two electical leads and remove tags.

6-5. GENERATOR SET WIRING HARNESS.

a. Remove (see figure 6-2). Refer to figure 6-2 and remove

wiring harness at terminal boards and connectors. On ASK equipped

generators, refer to Operator and Organizational Maintenance

Manual and remove cover assembly.

to reach. stability.

(c) Turn screw on R15 (or R16) clockwise

two additional turns.

(2) Operate Generator Set at 120 volts, single

phase load at 25%, 50%, 75%and100% load.

(3) If L1 to L3 voltage deviates more than 5%

over the load range, voltage regulator is defective.

b. Inspect (see figure 6-3).

b. Repair. Replace wires and terminals as needed. See table

6-2. (1) Drop the control box panel (28) by loosening

fasteners (9)toexpose the voltage regulator (39).

c. Install (see figure 6-2). Refer to figure 6-2 and install wiring

harness at terminal boards and connectors. On ASK equipped (2) Visually inspect the voltage regulator for poor

generators, refer to the Operator and Organizational Maintenance

Manual and install cover assembly. connection or burned or open components or cracked

circuit board.

6-8 Change 6
Wire No.

D26D16

D26E16

D26F16

D26G16

D26H16

D26J16

D26K16

P59G16

P60E16

P60F16

P60G16

P67A16

P67B16

P67C16

X4A8

X5A8

X6A8

X7B8

X7D16

X8B8

X8D16

X9B8

X9D16

X9E16

X110A8

X10B8

X10D16

X11A8

X11B8

X11D16

X12A8

X12B8

X12D16

X12E16

X13B8

X14B16

X15B16

X17B16

X22A16

X23A16

X28A16

TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only)

NOTE

All wires are copper, 600V, per MIL-W-5086/2.

Gauge

16

16

16

16

16

16

16

16

16

16

16

16

16

16

8

8

8

8

16

8

16

8

16

16

8

8

16

8

8

16

8

8

16

16

8

16

16

16

16

16

16

Marking

Color

black

black

black

black

black

black

black

red

red

red

red

red

red

red

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

black

Length

in Inches

21

17

17

32

15

3.5

34

24

22

19

20

19

20

22

16

16.5

15

12

13.5

18

19

10

17.5

17

19

15

35

20

19

35

21

17

22

22.5

20

20

15.5

14

Terminal Lugs

MS25036-107

MS25036-107, MS25036-108

MS25036-107, MS25036-108

MS25036-107, MS25036-153

MS25036-107, MS25036-108

MS25036-107

MS25036-107, MS25O36-153

MS25036-106

MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107, MS25036-107

MS25036-107

MS25036-107

MS25036-115

MS25036-115

MS25036-115

MS25036-115, MS25036-115

MS25036-108, MS25O36, 153

MS25036-115, MS25036-115

MS25036-108, MS25036-153

MS25036-115, MS25036-115

MS25036-108, MS25036-153

MS25036-108

MS25036-115

MS25036-115

MS25036-153, MS25036-108

MS25036-115

MS25036-115, MS25036-115

MS25036-153, MS25036-108

MS25036-115

MS25036-115, MS25036-115

MS25036-153, MS25036-108

MS25036-108

MS25036-115

MS25036-108

MS25036-108

MS25036-108

MS25036-153

MS25036-153

MS25036-153, MS25036-153

Change 2 6-8. 1
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 6-3.1. AC Output Control Box Wiring Harness (MEP-112A Only)

Marking Length

Wire No. Gauge Color in Inches Terminal Lugs

X29A16 16 black 19.5 MS25036-153

X30A16 16 black 14 MS25036-153, MS25036-107

X30B16 16 black 15 MS25036-107, MS25036-108

X30C16 16 black 32 MS25036-153, MS25036-107

X31A16 16 black 7 MS25036-107, MS25036-153

X31B16 16 black 22 MS25036-107

X32A16 16 black 16 MS25036-153, MS25036-108

X33A16 16 black 14.5 MS25036-153, MS25036-153

X34A16 16 black 17 MS25036-153

X35Al6 16 black 19 MS25036-153

X36A16 16 black 28 MS25036-153, MS25036-153

X37A16 16 black 28 MS25036-153, MS25036-153

X38A16 16 black 25 MS25036-153, MS25036-153

X39A16 16 black 26 MS25036-153

X40A16 16 black 21

X47A16 16

MS25036-153

black 22 MS25036-107, MS25036-153

X48A16 16 black 20.5 MS25036-107, MS25036-153

X49A16 16 black 16 MS25036-107, MS25036-153

X76A16 16 black 16 MS25036-153, MS25036-108

X77A16 16 black 34 MS25036-153

X31F16 16 black 35 MS25036-107, MS25036-153

6-8.2 Change 2
c. Remove.

(1) Tag and disconnect harness leads to voltage

regulator (39).

(2) Remove nuts (38) attaching voltage regulator

from control box (57) and remove voltage regulator.

d. Test, Bench (see figure 6-4).

(1) Connect ac voltage regulator to test circuit and

test as shown in figure 6-4. Transformers T1 and T2 are

located in the control cubicle (see figure 6-3, items 34 and

37) and may be disconnected and used for this test.

(2) Perform the test and calibration procedures

shown in figure 6-4.

(3) Failure of the voltage regulator to meet the test

and calibration requirements indicates the voltage regulator

should be replaced.

e. Repair. See voltage regulator schematic diagram,

figure 6-5 or 6-5.1.

(I) Repair of the voltage regulator is limited to

replacing defective components. Refer to the schematic figure 6-5 for proper values.

f. Installation (see figure 6-3).

NOTE

When replacing voltage regulator, be sure to

remove jumpers from old voltage regulator.

Install jumpers in the same location on the new

regulator. Failure to install jumpers correctly

will result in voltge regulator failure. If diftlculty

occurs in reconnecting jumpers, refer to figure

1-1orl-1.l.

(1) Mount serviceable voltage regulator (39) into

the control box (57) using nuts (38).

(2) Reconnect previously tagged and removed harness to the voltage regulator terminal board.

6-7. AC OUTPUT CONTROL BOX WIRING HARNESS.

Install and repair wiring harness by replacing wires, connectors, and terminal lugs as necessary. See figure 6-6 and tables

6-3,6-3.1 for all necessary wiring harness assembly.

6-8. AC OUTPUT CONTROL BOX ASSEMBLY.

a. Test, on Equipment.

(1) Resistor R3 (20, figure 6-10) must be adjusted

as follows before performing any tests.

(2) Remove wire D26F16 from TB3-1 and connect 0 to 1 amp ac ammeter. Connect test ammeter as shown

in figure 6-7.

(3) Place reconnection switch in 1200 position.

TM 5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(4) With the generator operating at rated frequency, apply rated load by closing circuit breaker (CB1) (9,

figure 6-10).

(5) Adjust R3 until ammeter previously installed

reads 0.6 amps, tighten locknut on R3. R3 is now adjusted

properly.

(6) Disconnect test equipment and proceed with

testing in accordance with test schedule.

NOTE

Because the proper connection of certain ac output control box circuits can only be determined

by its ability to function properly when operated

in conjunction with the control cubicle: it is

imperative that the control cubicle supplied be

complete and is functioning properly for all

tests.

(7) With the unit running normally, test control

box assembly by measuring voltage at load terminals with

the reconnection switch in each of its three positions. See

table 6-4.

b. Remove (see figure 6-8). Remove electrical connector plugs from connectors (2) on side of control box (1).

Remove two screws (3), lockwashers (4), bevel washers (5),

lockwashers (6), and nuts (7). Remove four screws (8) and

washers (9) attaching box to skid-base (10) and remove control box(l).

c. Install. Mount control box (1) to skid-base (10)

using screws (8), washers (9). and screws (3), lockwashers (4),

bevel washers (5), lockwashers (6), and nuts (7). Reconnect

plugs to connectors (2).

6-9. AC OUTPUT CONTROL BOX (INTERNAL

COMPONENTS).

WARNING

Before working on the load terminal board or

other devices associated with the ac control box,

make certain that the Generator Set is not operating, all switches are in the OFF or OPEN position, and there is no input to the load.

Table 6-4. Terminal Voltages

Switch Position

120V, 1 Phase

120/240 V, 1 Phase

120/208 V, 3 Phase

Measure

Across

L1-L3

L0-L1

L0-L3

L1-L3

L0-L1

L0-L2

L0-L3

L1 -L2

L2-L3

L1-L3

Correct

Voltage

120 vac

120 vac

120 vac

240 vac

120 vac

120 vac

120 vac

208 vac

208 vac

208 vac

Change 7 6-9
Figure 6-3.

6-10
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

1: Screw 20. Rheostat 39. Regulator

2. Nut 21. Switch

3. Holder

40. Link

22. Switch 41. Screw (2)

4. Terminal (2) 23. Switch 42. Nut (2)

5. Hook 24. Screw (2) 43. Relay

6. Screw 25. Circuit breaker 44. Screw (2)

7. Nut 26. Nut(4) 45. Nut(2)

8. Clamp 27. Screw (4) 46. Panel assembly

9. Fastener pin (3) 28. Panel 47. Screw (4)

10. Grommet (3) 29. Nut 48. Nut (4)

11. Stud (3) 30. Screw 49. Screw (4)

12. Battery indicator 31. Strap 50. Nut (4)

13. Lampholder (2)

14. Lamp (2)

32. Screw (2) 51. Screw (4)

33. Nut (2) 52. Nut (4)

15. Hourmeter 34. Transformer 53. Wiring harness

16. Frequency meter 35. Screw (4) 54. Screw (4)

17. Percent rated current meter 36. Nut (4) 55. Nut (4)

18. AC Voltmeter 37. Transformer 56. Frequency transducer

19. Knob (3) 38. Nut (4) 57. Control box

TS 6115-585-34/6-3(2)

Figure 6-3. Control Cubicle (Sheet 2 of 2)

a. Inspect.

(1) Load Terminal Board (TB1). Inspect the load

terminal board (10, figure 6-9) for physical damage.

Inspect the terminals for bad threads and security of

connections.

(2) Reconnection Switch (S6) (see figure 6-10).

Inspect reconnection switch (1) for physical damage.

Check that switch is securely attached to control box

(2) with four screws (3) and lockwashers (4) in front

and with two screws (5), spacers (6), lockwashers (7)

and nuts (8) in back. Check that electrical connections

to switch are clean and tight.

(3) AC Circuit Breaker (CB1) (see figure 6-10).

Inspect main circuit breaker (9) for physical damage.

Check that twelve electrical connections to breaker

are clean and tight. Check that breaker is securely

fastened to output control box.

(4) Printed Circuit Board Bridge Assembly (see

figure 6-9). Remove four screws (11) and lockwashers

(12) attaching side access panel (13) to output control

box (24) and remove panel. Inspect printed circuit

board (23) and components for physical damage. Check

that the assembly is clean and securely attached to

output control box. Check that electrical connections

to board are clean and tight.

(5) 15 Amp Circuit Breaker (CB3) (see figure

6-10). Inspect 15 amp circuit breaker (11) for physical damage. Check that two electrical connections to

breaker are clean and tight. Check that breaker is

securely attached to output control box (2).

(6) Convenience Receptacle (J14) (see figure

6-10). Inspect convenience receptacle (13) for charring or other physical damage. Check that two electrical connections to receptacle are clean and tight.

Check that receptacle is securely fastened to front

panel of output control box (2) with two screws (18)

and nuts (19). Check that receptacle cover (16) and

gasket (17) are securely attached to panel and that

cover operates properly.

(7) Linear Reactor (Ll) (see figure 6-9). Inspect

linear reactor (15) for physical damage. Check that

electrical connections are clean and tight. Check that

reactor is securely attached to side panel of output

control box.

(8) Connector Assemblies (see figure 6-9). Inspect each of the four connector assemblies (18 and

21) mounted to side of output control box for corrosion

or physical damage. Check that each connector assembly is securely mounted to side panel of output control

box.

(9) Current Voltage Transformer (CVT1) (see

figure 6-9). Inspect transformer (6) for physical

damage. Check that electrical connections to transformer are clean and tight.

(10) Current Transformer (CT1) (see figure 6-9).

Inspect transformer (7) for physical damage. Check

that electrical connections to transformer are clean

and tight.

(11) Wiring Harness Assembly. Inspect wiring

harness for broken wires. Check for frayed or deteriorated insulation. Check that all terminal points are

clean, tight, and free of damage.

Change 4 6-11
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 6-4. Testing Voltage Regulator

6-12 Change 7
Figure 6-5.

Change 7 6-13
Figure 6-5.1. AC Voltage Regulator Schematic (P/N 72-5338)

6-14 Change 7
Figure 6-7. AC Output Control Box Test Setup

(12) Output-Control Box Housing (24, figure 6-9).

Inspect output control box housing for physical damage.

Check that all hingeq covers, and latches operate properly.

Check that all nameplates are in place. Check that side

access cover is alwavs in date when box is being actively

serviced.

b. Test.

(1) Reconnection Switch (S6) (1, figure 6-10). Tag

and disconnect electrical connections except jumper wires

from reconnection switch. Using an ohmmeter check for

continuity between terminals listed in table 6-5 for each

of the three switch positions. If continuity is not found for

each pair of terminals listed, replace reconnection switch.

If continuity is found between any other terminals switch

should be replaced.

(2) AC Circuit Breaker (CB1). Test that breaker will

remain in both the ON and OFF positiona.

(3) 15 Amp Circuit Breaker (CB3). Test that breaker

will remain in both the set (pushed) and tripped (pulled)

positions.

(4) Convenience Receptacle (J14). With 15 amp

circuit breaker in proper operating position, test convenience receptacle using a 120 volt trouble light or

voltmeter. With the unit operating and the 15 amp

circuit breaker pushed in, 120 volts should be present

at the receptacle.

(5) Linear Reactor (Ll). Disconnect electrical

connectors from control box. Use an ohmmeter to check

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

resistance of each of the three windings in the reactor

by checking resistance between terminals 1 and 2, 3 and

4, 5 and 6. Resistance for each winding must be 13.5 ohms

plus or minus 1.35, if not replace reactor.

(6) Connector Assemblies. Test for continuity

between each pin and case for shorts to ground.

(7) Current Voltage Transformer (CVT1). Using an

ohmmeter check three primary windings of transformer

(figure 1-1, 6-7.1 and 6, figure 6-9) by measuring resistance

from terminals H1 to H2, H3 to H4, H5 to H6. Resistance

must be 2.27 ohms ± 0.227 ohms. Check resistance in three

secondary windings of transformer by checking from

terminals Xl to X2, Xl to X3, X2 to X3. Resistance

must be 1.68 ohms ± 0.168 ohms. Check resistance in

control windings by checking from terminals Cl to C2.

Resistance must be 9.6 ohms ± 0.96 ohms. If any of the

windings do not show the proper resistance, replace

transformer.

(8) Current Transformer (CT1). On the current

transformer (figures 1-1, 6-7.1 and 7, figure 6-9) only the

secondary windings can be checked. Using an ohmmeter

check resistance in secondary windings by checking from

terminals 1A to 2A, lB to 2B, lC to 2C. Resistance must

be 0.5 ohms ± 0.05 ohms. If any of the windings do not

show the proper resistance, replace transformer.

(9) Bridge Rectifier Assembly (A4) (see figure 6-11).

Tag and remove leads to terminal board and test each

diode (3) separately by checking between terminals (6)

shown in table 6-6. Resistance in one direction should be

very high in one direction and very low in the other.

Measure resistance of R1 (4). It should be 56 ohms.

Change 5 6-15
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Table 6-5. Reconnection Switch Continuity

6-16 Change 7
TM5-6115-585-34 TM5-6115-585-34

NAVFACP-8-623-34 NAVFACP-8-623-34

TO-35C2-3-455- 2 TO-35C2-3-455-2

TM-05684C/05685B-34 TM-05684C/05685B-34

Figure 6-7.1. CVT and CT Wiring

Change 5 6-16.1
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 6-8. AC Control Box Removal

6-16.2 Change 5
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

 Table 6-6. Testing Bridge Assembly (60 Hz Only)

To Test Diode

A4-CR1

A4-CR2

A4-CR3

A4-CR4

A4-CR5

A4-CR6

Check Resistance in Both

Directions Between Terminals

2-5

1-5

3-5

2-4

1-4

3-4

c. Removal.

(1) Reconnection Switch (S6) and Transformers

(CT1 and CVT1). Due to the large number of wires

connected to these items, they are removed from the

control box with the wiring connected. Remove screw

(3, figure 6-10) and lockwashers (4). Remove screws

(5), nuts (8), lockwashers (7) and spacers (6). Remove

switch (1) and wiring. Remove transformers (6 and 7,

figure 6-9) by removing screws (l), nuts (3) and lockwashers (2). Tag and remove wiring from transformers and switch. Disassemble transformers by

removing screws (4) and nuts (5).

(2) Load Terminal Board (TB1) (see figure 6-9).

Disconnect load from load terminal board. Remove

six screws (8) and lockwashers (9), attaching board

(10) to control box (24) and remove board. Tag and

disconnect four wires to load terminals (25).

(3) AC Circuit Breaker (CB1). Remove side access panel (13, figure 6-9) by removing screws (11)

and lockwashers (12). Tag and remove leads connected

to circuit breaker (9, figure 6-10). Remove six screws

(10) attaching breaker (9) to front panel (2) and remove breaker.

(4) 15 Amp Circuit Breaker (CB3) (MEP-003A

only) (see figure 6-10). Remove side access panel

(13, figure 6-9). Tag and disconnect two electrical

leads to 15 amp circuit breaker (11, figure 6-10).

Remove two screws (12) attaching breaker to front

panel of output control box (2) and remove breaker.

(5) Convenience Receptacle (J14) (MEP-003A

only). Remove four screws (11, figure 6-9) and lockwashers (12) attaching side access cover (13) to output control box and remove cover. Remove four

screws (14, figure 6-10) and nuts (15) attaching receptacle cover to front panel and remove cover (16)

and gasket (17). Tag and disconnect two leads from

receptacle. Remove two screws (18) and nuts (19)

attaching receptacle to front panel and remove receptacle (13).

(6) Linear Reactor (L1) (see figure 6-9). Remove

side access panel (13). Tag and disconnect six leads

to linear reactor (15). Remove four screws (14) attaching reactor to side panel of output control box and

remove reactor.

(7) Connector Assemblies (see figure 6-9). Remove screws (16 and 19) and nuts (17 and 20) attaching connectors (18 and 21) to output control box and

remove connector. Tag and disconnect wires from

wiring harness to connector. Reconnect tagged wires

to new connector.

(8) Bridge Rectifier Assembly (see figure 6-9).

Tag and remove leads to rectifier assembly (23). Remove nuts (22) holding bridge assembly to ac output

control box and remove bridge assembly. Replace bad

diodes or resistors as necessary.

d. Install.

(1) Load Terminal Board (TB1). Attach four

tagged wires to load terminals per wiring diagram,

figure 1-7. Attach load terminal board (10, figure

6-9) to control box (24) with six screws (8) and lockwashers (9).

(2) AC Circuit Breaker (CB1) (see figure 6-10).

Attach circuit breaker (9) to front panel of output

control box with six screws (10). Attach six tagged

leads to terminals 3, 4, 7, 8, 11, and 12 of breaker

per wiring diagram, figure 1-1. Replace side access

panel.

(3) 15 Amp Circuit Breaker (CB3) (MEP-003A

only) (see figure 6-10). Attach new breaker (11)

to front on output control box (2) with two screws

(12). Attach two tagged leads to 15 amp circuit

breaker per wiring diagram, figure 1-1.

Change 2 6-17
TM5-6115-585-34

NAVFACP-8-262-12

TO-35C2-3-455-2

TM-05684C-3 4

Figure 6-9 Output Control Assembly (Sheet 1 of2)

6-18
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

1. Screw (1O) 14. Screws (4)

2. Lockwasher (10) 15. Linear reactor

3. Nut (10) 16. Screw (12)

4. Screw (2) 17. Nut(12)

5. Nut (2) 18. Connector (3)

6. Transformer 19. Screw (4)

7. Transformer 20. Nut (4)

8. Screw(6) 21. Connector

9. Lockwasher (6) 22. Nut (4)

10. Load terminal board 23. Bridge rectifier assembly

11. Screw (4) 24. Output control box

12. Lockwasher (4) 25. Load terminal (4)

13. Access panel

Figure 6-9. AC Output Control Assembly (Sheet 2 of 2)

(4) Convenience Receptacle (J14) (MEP-003A

only) (see figure 6-10). Attach new receptacle (13) to front

panel with two screws (18) and nuts ( 19). Attach receptacle

cover (16) and gasket (17) to front panel with four screws

(14) and nuts ( 15). Attach two tagged leads to receptacle per

wiring diagram. figure 1- 1.

(5) Linear Reactor (L1) (see figure 6-9). Attach

new reactor ( 15) to side panel with four screws ( 14). Connect

six tagged leads to reactor per wiring diagram, figure 1-1.

(6) Connector Assemblies (see figure 6-9). Attach

connectors (18 and 21 ) to output control box with screws ( 16

and 19) and nuts (17 and 20).

(7) Reconnection Switch (S6) and Transformers

(CT 1 and’ CVT 1 ). Assemble transformers (6 and 7, figure

6-9) with screws (4) and nuts (5). Attach tagged wires to

transformers and reconnection switch (1, figure 6-10). Refer

to wiring diagram, figure 1-1. Install transformers (6 and 7.

figure 6-9) with screws (1). nuts (3), and lockwashers (2).

Install reconnection switch (1. figure 6-10) with screw (3).

lockwasher (4), screw (5), spacer (6). lockwasher (7), and nut

(8).

(8) Bridge Rectifier Assembly (see figure 6-

9). Position bridge assembly (23) to ac output control box

and attach with nuts (22). Connect electrical leads and

remove tags.

NOTE

If any difficulty is encountered in reconnecting the jumpers

 to the reconnection switch, refer to figure 6-10.1 and 6-10.2.

Change 7 6-19
Figure 6-10.

6-2 0 Change 2
Figure 6-10.1

TM5-6115-585-3 4

NAVFACP-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-3 4

Change 7 6-20.1
Figure 6-10.2

TM5-6115-585-3 4

NAVFACP-8-623-34

TO-35C2-3-455- 2

TM-05684C/05685B-34

6-20.2 Change 7
TM5-6115-585-3 4

NAVACP-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-34

Figure 6-11. Bridge Rectifier Assembly A-4

Change 6-21/(6-22 blank)

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 7

MAINTENANCE OF ENGINE

Section L DESCRIPTION AND FUNCTION

7-1. GENERAL. One piece, press fit oil seals are used to seal both

ends of crankshaft. A mechanical governor is used

The engine is a four cylinder, air-cooled, overhead to regulate engine speed under varying generator

valve, fuel injected, diesel. End crankshaft and cam- load conditions. Since the engine is direct coupled

shaft bearings are press fit one piece bearings. The to the generator, correct engine speed will produce

center crankshaft bearing is a two piece split bear- required generator output.

ing. Crankshaft end play is adjusted by using correct

shim between rear bearing plate and cylinder block.

Section II. ENGINE EXTERNAL ASSEMBLY

7-2. FUEL LINES.

a. Removal. On ASK equipped generators, refer to Operator and

Organizational Maintenance Manual and remove right panel assembly.

Tag and remove injector nozzle return line (3, figure 7-1). Remove

manifold (4) and return line (5). Tag and remove injector lines (7).

b. Inspection. Inspect lines and fittings for thread

damage and breaks which might cause leaks.

c. Installation. Remove plugs or tape from lines and fittings.

Contaminated lines and fittings should be rinsed with clean fuel oil

before installation. Install injector lines (7, figure 7-1) between injector

pump (1) and injector nozzles (2). Remove tags. Install return line (5)

and manifold (4). Install fittings (6) on injector nozzles (2) and install

return lines (3) between fittings (6) and manifold (4). Remove tags.

For torque information on fuel line fittings see Table 9-1 . On ASK

equipped generators, refer to Operator and Organizational Maintenance Manual and replace right panel assembly.

CONTROL ASSEMBLY.

a. Inspect (see figure 7-2). On ASK equipped generators, refer to

Operator and Organizational Maintenance Manual and remove right

panel assembly. Inspect governor linkage and springs for physical

damage, binding or excessive slack or wear. Check that linkage is

clean and free of dirt, grease, or oil or other obstructions. Check that

governor linkage moves freely. Check ball joints for smooth but not

loose fits.

b. Test. Operate engine until it reaches normal

operating temperature. Check frequency meter.

Frequency meter should indicate rated frequency

with no load. Apply full load to unit. Governor

should adjust engine speed to equal rated frequency

without hunting (alternate increasing and decreasing

of speed). Adjust engine sensitivity if necessary as

given below.

C. Adjust.

(1) Low Speed Adjustment. Adjust low speed

(1600 RPM MEP-003A or 1778 RPM MEP-112A) by

repositioning the control nut (7, figure 7-2) at the

attaching bracket located inside the engine access

door. The control knob should be pushed fully in before making the low speed adjustment. This reduces

tension on the spring (17) permitting governor arm

(3) to move the injector pump (2) to lower fuel position reducing engine speed.

(2) High Speed Adjustment. Adjust high speed

(2000 RPM for MEP-003A) (2200 RPM for MEP112A) by setting the maximum speed screw (18),

located at the front of the engine (clockwise decreases speed, counterclockwise increases speed)

with the control knob pulled fully out.

(3) Sensitivity Adjustment. Adjust governor sensitivity (no load to full load speed droop) by turning

the sensitivity adjusting ratchet (16) counterclockwise

(lower spring) for more sensitivity (less speed droop

when full load is applied) or clockwise (raise spring)

for less sensitivity (more speed droop when full load

is applied). If the governor is too sensitive, a rapid

hunting condition occurs (alternate increasing and decreasing of speed). Adjust for maximum sensitivity

without hunting.

d. Remove. Disconnect governor linkage (1) from

injector pump (2) and governor arm (3). Remove

governor arm (3) from governor shaft (4). Remove

cotter pin (5) and pin (6). Loosen nuts (7) and (8).

Remove clamp (10). Remove speed control cable (11).

Remove control bracket (12) from engine back plate

by removing screw (13), lockwasher (14) and nut (15).

Change 6 7-1
TM5-6115-585-3 4

NAVFACP-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-34

Figure 7-1. Injector Fuel Lines

7-2 Change 4
Figure 7-2.

7-3
Figure 7-3.

7-4
e. Replace. Using screws (13, figure 7-2), lockwashers (14), and nuts (15), attach governor control

bracket (12) to engine back plate. Attach speed control

cable (11) to governor arm (3) with pin (6) and cotter

pin (5). Attach governor arm (3) and governor linkage

(1) between governor and fuel injection pump (2). If

new ball joints are used on linkage, position the new

joints to obtain the same length or 1/32 inch more (1

turn = 1/32 inch) than the old linkage. If old linkage

length is not available, position new ball joints about

midway on each end linkage, then lengthen 1/8 inch.

DO not overspeed engine for

moment.

more than a

f. Preliminary Linkage Adjustment (figure 7-3.1).

The following adjustments shall be made before

starting the engine if the linkage was replaced.

(1) With link (1) compressed, adjust length between ball joints to 5-1/2 in.

(2) Set solenoid bumper screw to shut off position, dotted line (2), by loosening locknut (3) on solenoid plunger (4). With plunger down, adjust bumper

screw to push control unit post down, dotted line (5),

to maximum shutoff position.

(3) Hook governor spring (6) in the mid-range of

sensitivity ratchet (7).

(4) Manually move governor arm and linkage to

check for interference.

(5) Adjust position of upper ball joint in slot

(8) on governor arm (9) so link (1) does not bind

against fuel stop solenoid or hole (10). A slight contact of link to bottom of solenoid is permissible but

only at shut down. The fuel control unit should move

up to position (2A) when solenoid is energized with

start switch.

g. Final Linkage Adjustment. Perform the following steps to establish governor overshoot and undershoot, balancing external linkage movements within

the range of governor internal parts.

(1) Start engine and, with no load, adjust speed

control for rated frequency.

(2) Push linkage downward (11) about 1/4 in.

with light finger pressure. If the linkage appears to

reach governor internal travel limit (higher pressure

is felt), stop engine and lengthen linkage as required.

(3) Apply rated load and adjust speed control

for rated frequency.

CAUTION

Shortening the linkage too much in the following step will prevent no-load speed control,

or may cause a runaway engine.

h. Speed Droop Adjustment (figure 7-3.1 ). Droop

between no load and rated load is adjusted by rotating ratchet (7). Clockwise rotation decreases

droop; counterclockwise rotation increases droop.

Start engine and with no load, adjust speed control

for rated frequency. While observing the set freTM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

quency meter, change from no load to full load several times. Adjust to

minimum droop obtainable. Repeat as required. On ASK equipped generators, refer to Operator and Organizational Maintenance Manual and

replace right panel assembly.

Figure 7-3.1. Governor Linkage Adjustment

NOT E

If droop is too small, hunting (periodic frequency swings) will occur when changing from

no load to full range because the governor

will be too sensitive.

7-4. FLYWHEEL AND RING GEAR ASSEMBLY

a. Removal (see figure 7-3).

(1) Remove engine from set per paragraph 2-9.

(2) Remove timing pointer (10, figure 7-3) by removing screws (11).

(3) The flywheel (1) is a tapered fit on the

crankshaft (2). Remove flywheel mounting screw (3)

and washer (4). Support and remove flywheel and ring

gear assembly by using a two pronged wheel puller

inserted through the slots provided in the flywheel.

b. Clean and Inspect. Clean the flywheel and ring

gear assembly (1) using solvent. Check the ring gear

for broken or worn teeth.

c. Install. Replacement flyheels are supplied with

timing marks already stamped in place. The engine

must still be timed properly to this timing mark. The

only accurate method of determining the port closing

point is to measure piston travel. This is a critical

measurement and should be done only with accurate,

dependable equipment Mount flywheel keying

properly and tighten in place using screw (3) and

washer (4), (figure 7-3). With the flywheel mounted,

rotate flywheel counterclockwise until Number 1

cylinder is on its compression stroke, which follows

the closing of its intake valve. Remove the exhaust

rocker arm (3, figure 7-9), exhaust valve rotator (1,

figure 7-11). valve looks (2), spring retainer (3) and

spring (5), using fabricated tool (see figure 7-10).

Allow exhaust valve to drop down onto top of piston.

Rotate flywheel counterclockwise until piston is at

Change 6 7-5
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NAVFAC P-8-623-34

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TM-05684C/05685B-34

Top Dead Center. This can be measured on top of

exhaust valve stem with a dial indicator (see figure 7-

5).

NOTE

As the piston comes up to Top Dead Center

there is very little change in the dial indicator

reading and extreme care should be used to

establish the exact Top Dead Center.

Zero the dial indicator. Rotate flywheel in opposite

direction (clockwise) to a point where the dial indicator will indicate approximately 0.200 inch. Rotate flywheel counterclockwise slowly until dial indicator

shows 0.128 inch before Top Dead Center. Care must

be taken to insure that the valve is following the piston,

and that reading is accurate. This procedure must be

followed to insure that all slack is taken out of the

piston and connecting rod fits. At 0.128 inch before

Top Dead Center position, check timing pointer in

timing port on side of flywheel housing (5, figure 7-3).

The timing pointer (10) should be in exact alignment

with P.C. mark on flywheel. If pointer is net in alignment, move pointer, and remark generator adapter

as shown in figure 7-4. Destroy old alignment mark.

Figure 7-4. Timing Port and Port Closing Mark

7-5. FLYWHEEL HOUSING.

a. Remove flywheel per paragraph 7-4. Remove

flywheel housing (see figure 7-3). Remove screws (6),

lockwashers (7) and washers (8) while supporting

housing (5). Remove flywheel housing.

b. Clean and Inspect. Inspect flywheel housing for

cracks or dents. Wipe interior of housing with clean

cloth. Check to see that pointer is not bent and securely mounted.

c. Install. Mount flywheel housing (5) to the engine

using screws (6), lockwashers (7) and washers (8).

Figure 7-5. Measuring Top Dead Center

7-6. OIL COOLER.

a. Remove. Refer to Operator and Organizational

Maintenance Manual and remove oil cooler.

b. Clean and Inspect. In a suitable area clean oil

cooler using a brush and fuel oil. Inspect for leaks,

bent fins and/or bad inlet and outlet threads.

c. Test (see figure 7-6).

Figure 7-6. Testing Oil Cooler

7-6 Change 2
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C/05685B-M

Figure 7-7. Battery Charge Alternator and Blower Wheel

(1) Plug the oil cooler outlet using suitable plug. NOTE

(2) Connect the oil cooler in suggested test setup (see figure 7-6). Observe the arrangement of the conical

washers in the torsion damper assemblies.

(3) Apply 25 psi air pressure to the oil cooler. These washers must remain ‘in the same ar-

(4) Close the valve and monitor the pressure. A rangement of the originally assembled set or

drop in air pressure indicates a leak in the oil cooler. the function of the dampers will be impaired.

7-7. BLOWER WHEEL ASSEMBLY.

a. Inspect (see figure 7-7).

(1) Refer to Operator and Organizational

Maintenance Manual and remove blower housing.

(2) Check blower wheel (4) for cracks or broken

fins. Check for free play between blower wheel and

hub. Replace torsion damper assemblies (6) if free

play is present.

b. Removal. Remove screw (l), lockwasher (2) and

washer (3), attaching blower wheel to crankshaft. Use

two 5/16-24 screws in blower hub and a suitable

c. Repair. Blower wheel and hub are a balanced

unit and should not be disassembled. To replace torsion damper assemblies, remove screws, nuts, and

replace torsional dampers and reuse flat washers

and spacers as required for that type set. Torque

screws 28-30 ft-lb.

d. Install.

(1) Mount blower wheel assembly to crankshaft

using screw (l), lockwasher (2) and washer (3). Torque

screw (1) to 65-70 ft-lb.

(2) Refer to Operator and Organizational

puller to remove blower wheel (4) and key (5). Maintenance Manual and install blower-housing.

Change 2 7-7
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

7-8.

a.

BATTERY CHARGE ALTERNATOR. (2) With generator running, disconnect batteries

leaving 12 ohm resistor load in circuit to generator.

Inspect (see figure 7-7). The alternator should provide a dc voltage between

(1) Refer to Operator and Organizational

Maintenance Manual and remove blower housing.

(2) Check stator wiring and voltage regulator

wiring for loose connections or shorts. Check fuse F 1

(16).

b. Test on Equipment.

(1) Load the batteries with a 12 ohm, 200 watt

resistor (see figure 7-8). Run the set at rated frequency. The charge rate should be between 6.5 and

24 and 28.5 volts. -

c. Removal.

(1) Rotor. Refer to Operator an d

Organizational Maintenance Manual and remove the

blower housing. Remove blower wheel assembly (4,

figure 7-7) per paragraph 7-7. Remove rotor mounting

screws (9) and lockwashers (10) attaching rotor(11) to

blower wheel (4) and remove rotor (11).

(2) Stator. Disconnect stator leads (14, figure

7-7) from terminal block on engine back plate. Re -

move wire clamp from oil filter casting. Remove

screws (12) and lockwashers (13) attaching stator (15)

10 amperes. to engine and remove stator (15).

Figure 7-8. Resistively Loading the Batteries

7-8 Change 2
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

d. Clean and Inspect. Clean blower wheel, stator

and rotor with clean dry cloth. Inspect stator and

rotor for signs of friction wear. Check stator wires

for breaks, looseness and good insulation.

e. Test.

(1) Rotor. The rotor is a permanent magnet assembly and should not deteriorate.

(2) Stator. Using an ohmmeter, check the stator

for open circuitry. High pot test the stator to ground

for short circuits at 1070 volts.

f. Install.

(1) Stator. Attach stator (15) to engine using

screws (12) and lockwashers (13). Replace wire clamp

to oil filter casting. Reconnect stator leads (14) at

terminal block.

(2) Rotor. Install rotor (11) into blower wheel (4)

using screws (9) and lockwashers (10). Install blower

wheel per paragraph 7-7. Install blower housing per

Operator and Organizational Maintenance Manual.

Section III. ENGINE INTERNAL ASSEMBLIES

7-8.1. ENGINE COMPRESSION TEST.

The engine cylinder compression tests of this

paragraph may be used to determine the condition of

engine valves, pistons, piston rings, and cylinders.

Normal cylinder pressure should be between 350 to 450

psi, depending upon engine condition. Corrective

maintenance should be considered if cylinder pressure

is below 325 psi or if there is a pressure difference of 15

percent or more between cylidners. These pressure

ratings apply to a warm engine at cranking speed (approximately 300 rpm).

a. Compression Test.

(1) Run the engine until normal operating

temperature is reached.

(2) Stop engine and remove all injector nozzle

assemblies in accordance with paragraph 7-20a.

(3) Disconnect end tag wires to governor fuel shut

off solenoid (K5).

(4) Obtain or fabricate two compressing adapter

mounting studs (see table 2-2).

(5) Install two compression adapter mounting

studs (3, figure 7-8.1) into cylinder head (13) in place of

screws (1, figure 7-45).

(6) Assemble gasket (7, figure 7-8.1), adapter (8),

gasket (9), heat shield (10) and gasket (11) on compression adapter (6) (see table 2-l).

(7) Install compression adapter and assembled

parts into cylinder head opening (12) of cylinder head

(13).

(8) Install retainer flange (5) over compression

adapter studs (3), secure compression adapter (6) to

cylinder head (13) with two MS51967-2 nuts (2) (from

bench stock) and washers (4).

(9) Connect compression tester gage (1) (see table

2-1) to compression adapter (6).

(10) Crank the engine. Read and record cylinder

pressure as indicated by the compression tester gage.

(11) Remove nuts (2) from studs (3). Disassemble

and remove items 4 through 11 from cylinder head (13).

Diesel engines have very close clearances.

Too much oil squirted into the cylinder may

cause a hydrostatic lock and damage the

piston when the engine is cranked with compression adapter and tester gage installed.

(12) Squirt a small amount of oil (approximately 30

drops) into the cylinder through the cylinder injector

opening (12).

(13) Assemble and reinstall items removed in step

(11) above.

(14) Crank the engine. Read and record cylinder

pressure. If the cylinder pressure has increased considerably from the pressure recorded in step (10)

above, the rings and cylinder bore should be checked

for correct tolerances and wear limits.

(15) If the cylinder pressure has increased only

slightly, the mating surfaces of the valves should be

checked for abnormal conditions.

(16) Repeat steps 5 through 15 for each cylinder.

(17) Install injector assemblies in accordance with

paragraph 7-20i.

(18) Reconnect wires to governor fuel shut off

solenoid (K5).

Change 3 7 - 9
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NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

1. Compressor tester gage 8. Adapter

2. Nut (2) 9. Gasket

3. Compression adapter mounting studs (2) 10. Heat shield

4. Washer (2) 11. Gasket

5. Retainer flange 12. Cylinder injection opening

6. Compression adapter 13. Cylinder head

7. Gasket

Figure 7-8.1. Testing Engine Compression

7-10 Change 3
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NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

7-9.

a.

CYLINDER HEAD.

Removal (see figure 7-9).

(1) Remove. Refer to the Operator and

Organizational Maintenance Manual and remove air

shutter assembly and intake and exhaust manifold,

muffler and shroud assembly. Remove engine lifting

bracket, rocker cover and gasket, fuel nozzles, and

connecting oil lines to cylinder head.

(2) Remove rocker arms by removing the selflocking rocker arm nuts (1, figure 7-9), rocker arm

balls (2) on each rocker arm (3). Lift rocker arm (3)

off.

(3) Remove capscrews (4) and push rod guide

plate (5), screws (6) and washers (7) holding each

cylinder head (8) to cylinder block (9).

(4) Remove push rod (15) and remove cylinder

heads. If heads stick, rap sharply with a soft hammer.

DO not use a pry. Do not strike the cooling fins.

(5) Remove push rod shield (17) and packings (16),

spring (18) and washers (19).

(6) Remove cylinder head gaskets (10).

b. Disassembly (see figure 7-11).

(1) Remove valve rotator (l). Using a valve

spring compressor (see figure 7-10), disassemble

valve assemblies. Valve assemblies include spring

retainer lock (2), (see figure 7-11), retainer (3), valve

spring (5) and valves (8) and 10).

(2) Remove intake valve seals (4).

c. Clean and Inspect. Thoroughly clean all components of cylinder head assemblies. Remove all carbon

deposits from intake and exhaust ports and clean all

gasket surfaces. Inspect all cylinder head components

for physical damage. Inspect cylinder head firing deck

for warpage by measuring the maximum gap between

the cylinder head and a steel straightedge placed in

line and at a right angle to the cylinder head. If the

gap exceeds 0.0015” in any direction, replace cylinder

head.

d. Repair.

(1) Valves. Remove all carbon and check each

valve (8 and 10, figure 7-11) for burning, pitting or

warped head. Valves that are slightly pitted or burned,

refinish on a valve grinder. Refinish intake valves to

a 44” angle and exhaust valves to a 45° angle. But, if

they are badly pitted, or will have a thin edge when

refacing, replace them. Check refinished valves for a

tight seat to the valve seat (7) with an air pressure

type testing tool or by applying Prussian Blue on the

valve face and rotating it against the seat.

(2) Valve Guides. Check valve guides (6 and 9,

figure 7-11) to valve clearance. See table 1-2. If the

proper clearance cannot be obtained by replacing

valve, replace valve guides. Drive the old valve guides

into valve chambers. Drive new intake guides (6) in

until the y protrude 11/32 inch from the rocker cover

side of the head. Ream new valve guide to obtain the

proper clearance. Exhaust guides (9) should protrude

5/8 inch from rocker cover side of the head.

(3) Valve Seats. If the valve seats (7, figure

7-11) are pitted, refinish them. Using seat grinding

equipment, reface each seat to a 45° angle. Seat width

should be 3/64 to 1/16 inch for exhaust and 1/16 to

3/32 for intake. A seat can be refaced several times

before it becomes necessary to replace it. If, however, the valve seats are loose or cannot be refaced,

replace them. Adjust tool to cut 1/64 inch from edge

of seat. Oil the pilot to prevent it from seizing in the

valve guide. Cut each seat down to a narrow ridge on

edges and bottom and break it out with a sharp tool.

Change 3 7-10.1
TM5-6115-585-3 4

NAVFAC P-8-623-34

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TM-05684C/05685B-34

Figure 7-9. Cylinder Head Removal

7-10.2 Change 4
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-10. Valve Spring Removal

7-11
TM5-6115-585-34

NAVFACP-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-11. Cylinder Head Assembly

7-12
TM5-6115-585-34

NAVFAC P-8-623-34

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TM-05684C/05685B-34

Be careful not to cut into counterbore bottom. See

figure 7-12. Thoroughly clean valve seat counterbore

and remove’ any burrs from the edges. Drive new

valve seat inserts into place. Be certain that each seat

rests solidly on bottom of counterbore at all points.

To make installation easier, heat cylinder head in an

oven at 325°F (163°C) for about l/2-hour. Face each

new seat to a 45° angle. The finished seat face should

contact approximately center of the valve face. Use

Prussian Blue on each valve face to check this. Make

any corrections on the seat, not the valve face. When

new seats are installed and faced, insert valve into

each seat and check clearance from valve head to the

face of cylinder head. This must be at least 0.030

inch. If it is not, regrind the seat.

(4) Valve Springs. Check valve springs (5, figure

7-1 1) on a compression scale. Valve spring data is

given in the table 1-2. Replace any spring that is

weak, cracked or pitted or has ends out of square.

(5) Push Rods. Check that push rod is absolutely

straight. Replace bent or worn push rods.

e. Reassemble.

(1) Push a valve stem oil seal assembly (4) onto

each intake valve guide (6, figure 7-11). Then oil inside surface of each seal.

(2) Oil the stem of each valve (8 and 10, figure

7-11) and insert each in its own guide (6 and 9). If intake valve (8) is removed with seal in place on guide,

wrap sharp edge of valve notch with cellophane tape

to protect seal bore.

(3) Check each valve for a tight seat.

(4) Using a valve spring compressor (see figure

7-10), compress each valve spring and insert the valve

spring retainer (3, figure 7-11) and retainer locks (2).

Install valve rotator (l).

f. Install (see figure 7-9).

(1) Place head assemblies (8) and gaskets (10)

on cylinder block (9). Install springs (18), washers

(19) and packings (16) on push rod shields (17) and

install assembled push rod shields in cylinder block.

Lift back side of cylinder head and place push rod

shields in place, lower cylinder head in place. Use an

anti-sieze compound on head bolt threads and thread

bolts (4 and 6) and washer (7) into cylinder block (9).

Do not tighten head bolts at this time.

(2) Refer to Operator and Organizational

Maintenance Manual and install intake manifold.

Torque bolts 13-15 ft-lbs (see table l-l). Bend over lock

tabs. Now tighten head bolts 44 to 46 ft-lbs (see table 1-

1) following the sequence in figure 7-13.

Figure 7-12. Valve Seat Replacement

(3) Refer to Operator and Organizational

Maintenance Manual and install mufflers.

CAUTION

Install push rod with longer shouldered

end toward rocker arm.

(4) Install push rods (15, figure 7-9), rocker

arms (3), rocker arm balls (2) and rocker arm nuts

(l).

(5) Set valve clearance per Operator and

Organizational Maintenance Manual.

(6) Refer to Operator and Organizational

Maintenance Manual and install air shutter assembly

and shroud assembly.

NOTE

After the first 50-hours of operation,

valve clearance.

7-10. PISTON AND CONNECTING ROD.

read just

a. General (see figure 7-14). Each piston (7) is

fitted with three compression rings and an oil control

ring (4). Full floating piston pins connect the piston to

the connecting rod. The pins are held in place with a

retaining ring (5) at each end. The lower end of each

connecting rod contains half shell, precision bearings

(11) and the upper end contains reamed bushings (13).

Change 4 7-13
TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 7-13. Cylinder Head Bolt Tightening Sequence

7-14 Change 4
TM5-6115-585-34

NAVFACP-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-14. Piston and Connecting Rod

7-15
Figure 7-15.

7-16
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

1. Oil base 12. Center cam-shaft bearing 24. Shim

2. Gasket 13. Rear camshaft bearing 25. Thrust washer (2)

3. Screw (10) 14. Plug 26. Keys (3)

4. Lockwasher (10) 15. Retaining ring 27. Bolt (2)

5. Washer (10) 16. Crankshaft washer 28. Washer (2)

6. Bolt (8) 17. Crankshaft gear 29. Center bearing housing

7. Bearing (8) 18. Packing 30. Dowel

8. Cap (4) 19. Rear bearing plate 31. Lower bearing

9. Connecting rod (4) 20. Screw (6) 32. Upper bearing

10. Piston assembly (4) 21. Lockwasher (6) 33. Crankshaft

11. Front camshaft bearing 22. Crankshaft end bearing (2) 34. Cylinder block

23. Gasket

TS 6115-585-34/7.15(2)

Figure 7-15. Crankshaft Pistons and Connecting Rod (Sheet 2 of 2)

NOTE

The connecting rod and cap are stamped for

installation in the proper cylinder. When re -

moving piston assemblies, check the marking

so each piston can be installed in the proper

cylinder.

b. Removal (see figure 7-15).

(1) Drain crankcase oil and remove oil base (1)

and gasket (2) by removing screw (3), lockwasher (4)

and washer (5).

(2) Remove screws (13, figure 7-19), lockwasher

(12), bracket (11) and remove oil cup assembly (10).

(3) Remove cylinder head (paragraph 7-9) and

remove all carbon at the top of the cylinder bore. Remove ridge from cylinder bore before removing

piston.

(4) Remove bolts (6, figure 7- 15), cap (8) and

bearings (7) from each connecting rod (9) and push the

piston assembly (10) upward through top of cylinder

bore with a soft wooden tool to prevent rod bearing

damage. Loosely install cap (8) and bearings (7) on

the corresponding removed piston assembly to maintain proper grouping.

c. Disassembly (see figure 7-14).

(1) Using a ring expander, remove piston rings

(1, 2 and 4) and oil ring expander (3) from each piston.

(2) Remove two retaining rings (5) and push piston

pin (6) from each piston.

d. Inspect and Repair.

(1) Pistons. Thoroughly clean and inspect each

piston. Clean carbon from ring grooves and be sure

all oil holes are open. If any piston is badly scored

or burred, loose in cylinders, has badly worn ring

grooves or otherwise is not in good condition. redate

it. Check the piston clearance- in cylinder 90° “from

axis of piston pin and below oil control ring (4, figure

7- 14). Clearance should be 0.0062 to 0.0082 inch. If

not, replace piston and check cylinder wall for possible reconditioning.

(2) Piston Pins. Each piston pin should be a

thumb push fit into its piston at room temperatures.

Figure 7-16. Piston Ring Installation

7-17
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

If pin is excessively loose, install a new piston and

pin assembly.

NOTE

Piston and pins are matched sets and are not

procured separately.

(3) Rings. Place each piston ring into its cylinder

bore and using a feeler gauge measure gap dimensions. Gap is shown in Table l-2 If gap is under 0.010

inch, file

(a)

(b)

(c)

as follows:

Place file in vise.

Grasp piston ring in both hands.

Insert file into ring gap and move ring down

the entire length of file. Be sure-to apply equal-pressure on the ring.

(4) Connecting Rods (see figure 7-17). Clean connecting rods and check each for defects. Check connecting rod bushings for proper clearance with piston

pin. Clearance is given in Table 1-2. If bushings (13,

figure 7-14) are excessively worn, press them out and

install one new bushing from each side of bushing

bore. Press new bushings only until flush with sides

of rod to leave 1/16 to 7/64 inch oil groove in center.

Ream bushing I.D. to obtain the proper clearance.

Check bore in connecting rod. Bore must be open.

Check connecting rod alignment on a standard align-

(5) Connecting Rod Bearings (see figure 7- 17).

Inspect connecting rod bearings for burrs, breaks,

pits and wear. Measure clearance between bearings

and crankshaft journal. See Table 1-2 for clearance. If

necessary, replace with new standard or undersize

precision bearings.

e. Assembly (see figure 7-14).

NOTE

The piston witness mark (notch) must face

front of engine and rod witness marks (numbers) must face toward camshaft side of engine.

(1) Install connecting rods (12, figure 7- 14) on

each piston (7) with pins (6) and retaining rings (5).

If new bushings (13) were installed, check to see that

ends are flush with the connecting rod (12) to provide

for oil recess in the center.

(2) Install rings and oil ring expander (1, 2,3 and

4) on each piston (7). Compression rings will be

marked TOP or identified in some other manner.

Place this mark toward the closed end of piston.

Space ring gaps 1/4 of the way around piston from

one another. No gap should be in line with piston pin.

Oil the rings (1, 2 and 4) and pistons (7).

NOTE

ment fixture.

When installing old bearings make sure they

are installed in the same position they were

removed from.

Figure 7-17. Connecting Rod and Bushings

(3) Position a bearing half (11) in connecting rod

(12) and cap (10). Be sure there is no dirt under bearing. This could cause high spots and early bearing

failure.

f. Install,

(1) Hone cylinder walls. Clean and oil the cylinder walls. Install each piston in proper cylinder using

a suitable installer. Each piston assembly should be

installed with notch on piston toward front of engine.

The notch on the circumference of the closed end of

the piston should be located closest to front of engine.

(2) Position each connecting rod on crankshaft

and oil the journal and install rod cap with bearing

half. When installing rod cap, position so raised witness mark on the forging matches the mark on connecting rod. See figures 7-17 and 7-18. The piston

witness mark should face front and rod witness marks

toward camshaft side of engine.

(3) Tighten capscrews to specified torque. See

table 1-1.

(4) Turn engine over by hand to see that all

bearings are free.

7-18
After

main

using

NOTE

installation of new connecting rod or

bearings, clearances should be checked

plastic gauge.

(5) Install oil base (1, figure 7-15) with a new

gasket (2) using screws (3), lockwasher (4) and

washer (5).

(6) Install cylinder heads using proper bolt tightening sequence (see figure 7-13).

7-11. OIL PUMP.

a. Remove.

(1) Refer to paragraph 7-14 and remove gear

cover.

(2) Refer to paragraph 7-10 and remove oil base

assembly and oil cup assembly.

(3) Remove crankshaft gear lock ring (14, figure

7-19), gear (16) and retaining washer (15). At this

time the crankshaft gear (16) should be inspected for

signs of wear.

(4) Hold the pump (19) while removing attaching

screws (17) and lockwashers (18). Remove pump.

b. Clean and Inspect.

(1) Inspect oil passages. Clean with stiff wire

and wash out with fuel oil if necessary.

(2) Rotate pump drive gear and check that it rotates smoothly without binding.

c. Install (see figure 7-19).

(1) Install gear (16), retaining washer (15), and

lockring (14).

(2) Fill pump intake and outlet with oil to be sure it

is primed.

(3) Mount pump on engine using screws (17) and

lockwashers (18). Allow pump drive gear to crankshaft gear clearance. Failure to allow clearance can

damage oil pump.

(4) Install oil cup assembly (10) into pump.

(5) Install bracket (11) on center main bearing

housing and secure with lockwasher (12) and screw

(13).

(6) Install oil base (refer to paragraph 7-10).

(7) Install gear cover (refer to paragraph 7-14).

7-12. OIL FILTER ADAPTER ASSEMBLY.

a. Removal.

(1) Refer to the Operator/Crew and Organizational Maintenance Manual and remove the oil filter,

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-18. Connecting Rod Installation

oil pressure switch and oil lines connected to the oil

filter adapter.

(2) Remove screws (23 and 24, figure 7-19) and

lockwashers (25) and remove oil filter adapter (26)

and gasket (27). Discard gasket.

b. Inspection. Clean and inspect oil filter adapter

for damaged threads. Check oil passages for obstruction and clean if necessary.

c. Installation.

(1) Clean all gasket material from oil filter

adapter (26, figure 7-19) and cylinder block. Attach

oil filter adapter (26) and new gasket (27) to cylinder

block with screws (23 and 24) and lockwashers (25).

(2) Refer to the Operator and Organizational

Maintenance Manual and install the low oil pressure

switch, oil filter and oil lines on the oil filter adapter.

7-13. OIL BY-PASS VALVE.

a. Test on Equipment (see figure 7-20). High oil

pressure may be caused by the by-pass valve plunger

sticking closed. Low oil pressure may be caused by

the by-pass valve plunger sticking open. If these conditions exist, clean and inspect by-pass valve.

7-19
Figure 7-19.

7-20
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

1. Gear cover

2. Gasket

3. Screw (4)

4. LockWasher (4)

5. Washer (4)

6. Screw

7. Lockwasher

8. Oil base

9. Gasket

10. Oil cup assembly

11. Bracket

12. Lockwasher

13. Screw

14. Lock ring

15. Washer

16. Gear

17. Screw (2)

18. Lockwasher (2)

19.

21.

22.

23.

24.

25.

26.

27.

oil pump

Back plate

Rear bearing plate

Oil by-pass valve

Screw (2)

Screw (2)

Lockwasher (4)

Oil filter adapter

Gasket

TS 6115-585-34/7-19 (2)

Figure 7-19. Oil Pump Removal (Sheet 2 of 2)

b. Remove.

(1) Remove generator, engine flywheel, and

adapter.

(2) Unscrew recessed plug (1, figure 7-20) in

rear bearing plate (4).

(3) Lift out by-pass spring (2, figure 7-20) and

valve plunger (3).

Figure 7-20. Oil By-pass Valve

c. Cleaning and Inspection.

(1) Thoroughly clean spring (2, figure 7-20) and

plunger (3). Replace defective or worn parts.

d. Test. Determine proper valve operation by checking spring and plunger against the following values.

(1) Plunger diameter should be 0.3365 inch to

0.3380 inch.

(2) Spring free length should be 2-5/16 inches ±

1/16 inch. Spring force should be 2.25 ± 0.11 pounds

when spring is compressed to a length of 1-3/16

inches.

e. Installation.

(1) Assemble spring (2, figure 7-20) and plunger

(3) and install in bearing plate (4).

(2) Install plug (l).

7-14. GEAR COVER ASSEMBLY.

a. Inspect (see figure 7-21).

(1) The governor shaft is supported by two sets

of needle bearings and should not show signs of binding when rotated through its free travel.

(2) The oil seal should be inspected for leaks and

damage.

b. Removal.

(1) Refer to Operator and Organizational

Maintenance Manual and remove starter lockout

switch. Remove governor arm (3, figure 7-2) by

loosening screw (3, figure 7-22).

(2) Refer to Operator and Organizational

Maintenance Manual and remove blower housing.

(3) Refer to paragraphs 7-7 and 7-8 and remove

blower wheel and stator.

(4) Remove screw from oil filter adapter. Remove screws (1, figure 7-21), lockwasher (2), flatwasher (3), screw (4), lockwasher (5) holding gear

7-21
Figure 7-21.

7-22
Figure 7-21.

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-22. Gear Cover Components

7-23
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

cover (6) to crankcase. Tape crankshaft keyway to

prevent damage to seal. To loosen gear cover, tap it

with a soft hammer. Remove gasket (7).

c. Disassemble and Inspect.

(1) Governor Shaft (see figure 7-22). The governor shaft (5) is supported by two sets of needle bearings (7). To remove shaft, remove retainer (1) and

yoke (2) and pull shaft (5) from gear cover (13). If

shaft is binding, clean bearings, if loose, replace

bearings. To remove larger bearing (7) drive bearing

oil seal (11) out from the outside of gear cover. Remove smaller bearing (8) with bearing puller. Press

new bearings and oil seal into place.

(2) Gear Cover Oil Seal (see figure 7-22). Replace oil seal if damaged or worn. Drive old seal

(11) out from inside gear cover (13). Lay cover on a

board so seal boss is supported. Insert new seal from

inside with rubber lip and closed case toward outside

of gear cover and drive it flush with outside surface,

d. Reassemble.

(1) Work governor shaft to check for binding and

see that governor- shaft-end-thrust ball is in place

(see figure 7-23).

(2) Turn governor yoke so smooth side (convex

surface) is toward governor cup (12, figure 7-22) on

camshaft.

(3) Turn governor cup so the stop pin (figure 7- 23)

in the gear cover will fit into one of the holes in cup

surface. Measure the distance from end of roll pin to

mounting face of the cover. It should be 25/32 inch.

If it is not, replace pin. Pin should be positioned with

open end facing crankshaft seal.

7-24

Figure 7-23. Gear Cover Inspection
e.

wit h

Install (see figure 7-21).

(1) Pack the cavity between the two oil seal lips

grease per MIL-G-23827.

(2) Tape keyway and sharp edges on crankshaft

to protect the oil seal during installation.

(3) Mount gear cover (6) on engine using new

and flatwasher (3). Tighten mounting screws to specified torque. See table 1-1. Before tightening screws,

be sure stop pin is in governor hole.

(4) Refer to Operator and Organizational Maintenance Manual and install starter lockout switch.

(5) Connect governor arm (3, figure 7-2) to

governor shaft (5, figure 7-22) and tighten screw (3).

(6) Refer to paragraphs 7-7 and 7-8 and install

stator and blower wheel.

(7) Refer to Operator and Organizational Maintenance Manual and install blower housing.

7-15. GOVERNOR CUP.

a. Remove (see figure 7-24). On ASK equipped generators, refer

to Operator and Organizational Maintenance Manual and remove

cover assembly. Remove retaining ring from camshaft center pin and

slide cup off. Be sure to catch the ten flyballs that will fall out when

cup is removed.

b. Repair. Replace any flyballs that have flat spots

or grooves. Replace cup if race surface is grooved

or rough. The governor cup must be a free spinning

fit on camshaft center pin, but should be replaced if

excessively loose or wobbly. Check distance the

center pin extends from the camshaft gear, this distance must be 25/32 inch to give proper travel distance for the cup (see figure 7-24). If it is less, the

engine may race; if more, the cup will not hold the

balls properly. If distance is too great, drive or

press center pin in. If it is too small, replace pin; it

cannot be removed without damaging the surface. If

aluminum ball spacer openings are badly worn, replace ball spacer. Remove self-locking flat head

screws, install new screws, ball spacer and plate.

c. Install. To install governor assembly, fill flyball recesses with

grease MIL-G-23827 and install flyballs. Position governor cup on

shaft and install retaining ring. On ASK equipped generators, refer to

Operator and Organizational Maintenance Manual and replace ASK

cover assembly.

7-16. CAMSHAFT ASSEMBLY AND TAPPETS.

a. Removal.

(1) Refer to Operator and Organizational

Maintenance Manual and remove blower housing.

(2) Refer to paragraph 2-9 and remove engine.

(3) Refer to Operator and Organizational

Maintenance Manual and remove rocker arm covers.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 7-24. Governor Cup Assembly

(4) Refer to paragraph 7-14 and remove gear

cover.

(5) Refer to paragraph 7-18 and remove fuel injection pump.

(6) Remove crankshaft gear retaining washer (9,

figure 7-21) by removing lock ring (8) on the crankshaft.

(7) Refer to paragraph 7-9 and remove rocker

arms and push rods.

(8) Refer to paragraph 7-10 and remove oil base.

(9) Lay engine on side to avoid dropping tappets

(28) and remove camshaft assembly (15) as a group.

If necessary, pry it out with a screwdriver between

camshaft gear and crankcase. Remove retaining ring

(16) and press gear (17) off camshaft.

(10) Remove the valve tappets (28). These can be

removed only from bottom of crankcase.

(11) Refer to paragraph 7-17 and remove crankshaft gear.

Change 6 7-25
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(12) Remove back plate (22) and gasket (23) by

removing screws (19), screws (21) and lockwashers

(20).

(13) Camshaft Bearings. The camshaft bearings

(25, 26 and 27, figure 7-21) should be replaced if

clearance to camshaft is greater than specified, bearings show cracks breaks, burrs, excessive wear, or

other defects. The camshaft to bearing clearance

should be 0.0012 to 0.0037 inch. To check rear bearing (25) remove expansion plug (24) at rear of crankcase.

b. Cleaning and Inspection. If a cam lobe has become slightly scored, dress it smooth with a fine

stone. If camshaft is badly worn or scored, replace it.

c. Installation.

(1) Press new camshaft bearings into place. See

figure 7-25 for proper placement. Press rear bearing flush with bottom of expansion plug recess. Press

front bearing in flush with crankcase front surface

so oil passages are aligned. Do not attempt to ream

bearings, they are a precision type. After rear bearing is installed, insert a new expansion plug in recess, using sealing compound, and expand it into place

with sharp blows at its center.

(2) Install new gasket (23, figure 7-21) and back

plate (22) with screws (19 and 21) and lockwashers

(20).

(3) Refer to paragraph 7-17 and install crankshaft gear.

(4) With engine laid on its side, install tappets (27,

figure 7-21).

(5) Install key (18, figure ?-21) on camshaft (15),

press on gear (17) and install retaining ring (16).

(6) Install camshaft assembly (15) in engine

making sure tappets (26) are in place on push rods.

Align timing marks on camshaft gear and crankshaft

gear (see figure 7-26). Check gear lash (see figure

7-27).

(7) Install oil base per paragraph 7-10.

(8) Install crankshaft gear retaining washer (9,

figure 7-21) and retaining ring (8) on the crankshaft.

(9) Refer to paragraph 7-9 and install rocker

arms.

(10) Refer to paragraph 7-18 and install fuel

NOTE injection pump.

Expansion plug must not protrude from rear

face of crankcase.

(11) Refer to paragraph 7-14 and install gear

cover.

Figure 7-25. Camshaft Bearing Installation

7-26
Figure 7-26. Crankshaft and Camshaft

Gear Timing Marks

(12) Refer to Operator and Organizational

Maintenance Manual and install rocker arm covers.

(13) Refer to paragraph 2-9 and install engine.

(14) Refer to Operator and Organizational

Maintenance Manual and install blower housing.

7-17. CRANKSHAFT AND MAIN BLOCK BEARINGS.

a. Removal (see figure 7-15).

(1) Refer to Operator and Organizational

Maintenance Manual and remove blower housing.

(2) Refer to paragraph 2-9 and remove engine.

(3) Refer to paragraph 7-7 and remove blower

wheel.

(4) Refer to paragraph 7-8 and remove alternator

stator.

(5) Refer to paragraph 7-14 and remove gear

cover.

(6) Refer to paragraph 7-9 and remove cylinder

heads.

(7) Refer to paragraph 7-4 and 7-5 and remove

flywheel and housing.

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-27. Timing Gear Backlash

(8) Refer to paragraph 7-10 and remove oil base.

(9) Refer to paragraph 7-11 and remove oil pump

. . cup assembly.

(10) Remove lock ring (15) and retaining washer

(16) in front of crankshaft gear (17).

(11) Pull off crankshaft gear. It has 2- 1/4-20 UNC

tapped holes for attaching a gear pulling ring (see

figure 7-28). Use care not to damage teeth if gear is

to be re-used. Remove woodruff keys (26, figure 7- 15).

(12) Refer to paragraph 7-10 and remove connecting rod and piston assemblies.

(13) Remove rear bearing plate (19, figure 7-15)

from crankcase. Remove gasket (23) and shims (24).

7-27
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-28. Crankshaft Gear Removal

(14) Remove center main bearing housing (29)

and center bearings (31 and 32) and remove crankshaft (33) through rear opening in crankcase.

b. Clean and Inspect.

(1) Crankshaft. Clean crankshaft and blowout all

oil passages. Check journals for out-of-round, taper,

grooving or ridges. Pay particular attention to ridges

or grooves on either side of oil hole areas. Unusual

conditions here often point to previous neglect of oil

changes. If journal dimensions are not within limits

or journals are scored, metallize and regrind crankshaft to standards.

(2) Bearings. Replace bearings if clearances are

greater than limits (see table 1-2), or if bearings are

worn, grooved or broken.

(3) Rear Oil Seal. Inspect seal for wear or damage which might cause it to leak.

c. Rebuild Crankshaft. If crankshaft requires regrinding, metallize and regrind to standards. Special

procedures must be observed when reworking diesel

crankshafts. In addition to regrinding, the crankshaft

must be shot -peened and super-finished. Failure to

shot-peen the crankpin fillets is likely to cause early

failure. When the shaft is reground, follow this data

and figure 7-29 to shot-peen each crankpin fillet.

(1) Almen gauge reading, 0.012-A.

(2) Peen with 0.019 inch diameter cast steel shot.

(3) Peen for 30-seconds on each crankpin fillet.

7-28

Figure 7-29. Crankshaft Peening

(4) Mask off connecting rod bearing areas.

d. Installation.

NOTE

After each installation step, check crankshaft

to be sure it is not frozen in place.

(1) Heat cylinder block (34, figure 7-15) and bearing plate (19) at 325° F (163° C) in an oven 30 minutes

and press front and rear main bearings (22) into place,

aligning bearing housing oil holes (see figure 7-30).

(2) Install thrust washers (25, figure 7-15) on

locking pins (see figure 7-30).

(3) Oil bearing surfaces and install crankshaft

(33, figure 7-15) from rear of crankcase, through

rear bearing plate hole.

(4) Set the upper half of the center main housing

(29) on the crankshaft (33) and rotate it into place. Be

sure it is installed with the side marked f rent toward

the crankshaft gear. Set the two positioning dowels

(30) on the upper bearing mount. Install the center

main bearing cap (29) and torque the bolts (27) to 97-

102 ft-lbs.

(5) Place gasket (23) on each side of shim (24).

(6) Before installing bearing plate, tape keyway

and sharp edges on crankshaft to protect the oil seal
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C-34

Figure 7-30. Crankshaft Bearing Installation

during installation. Mount and secure rear bearing

plate (19).

(7) Check crankshaft end play (see figure 7-31).

Use enough rear bearing plate shims to provide 0.010

to 0.015 inch end play. If more than 0.010 inch total

thickness is required then use a steel shim of proper

thickness and an 0.005 inch thick gasket on each side

of shim. This avoids excessive gasket compression

and maintains bolt torque. Shims are available in

0.005, 0.010, 0.015, and 0.020 thickness.

(8) Install keys (26, figure 7-15) on crankshaft

(33), then drive gear (17) into place using fabricated

tool (see table 2-2). Install retaining washer (16) and

lock ring (15).

(9) Refer to paragraph 7-10 and install rod and

piston assemblies.

(10) Refer to paragraph 7-4 and 7-5 and install

flywheel and housing.

(11) Refer to paragraph 7-11 and install oil pump

cup assembly.

(12) Refer to paragraph 7-10 and install oil base.

(13) Refer to paragraph 7-14 and install gear

cover. Figure 7-31. Crankshaft End Play Measurement

7-29
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

(14) Refer to paragraph 7-8 and install alternator

stator.

(15) Refer to paragraph 7-7 and install blower

wheel.

(16) Refer to paragraph 7-9 and install cylinder

heads.

(17) Refer to Operator and Organizational

Maintenance Manual and install blower housing.

7-18. FUEL INJECTION PUMP.

a. Removal (see figure 7-32). On ASK equipped generators,

refer to Operator and Organizational Maintenance Manual and

remove top panel end right panel assemblies.

(1) Snap off governor linkage from injection pump (l), and

governor control arm and remove linkage.

Figure 7-32. Injection Pump

(2) Refer to paragraph 7-2 and disconnect inlet

and fuel return lines from pump. Tag and disconnect

high pressure lines at injector nozzle end at injector

pump. .

NOTE

All fuel connections must be plugged or capped

to prevent contamination.

7-30 Change 6

(3) Remove four hexagon nuts (2, figure 7-32),

lockwashers (3), and flatwashers (4) holding pump (1)

to crankcase and lift pump off crankcase. Be careful

to retain the shims (5) between the crankcase and

pump. The correct thickness of shims as stamped on

the crankcase is important to proper pump operation;

it provides the proper gear lash. This thickness does

not change when a new pump is installed. It changes only when

a new cylinder block is installed. To calculate new shim thickness

measure between camshaft and engine block pump mounting surface. Substract that measurement from 1.171 inches. This will be

the shim thickness. Refer to figure 7-33A. Use Gage, Depth,

Micrometer NSN 5210-00-542-4602 for this measurement.

(4) When removing a pump for replacement, record the button thickness and port closing dimensions

as stamped on the side of the pump mounting flange

(figure 7-33). These values are important in timing a

new pump to the engine.

b. Disassembly (see figure 7-34). All work on injection equipment MUST be performed in the cleanest

location possible. No filing, scraping or sawing should

be done on the bench where repairs are made.

(1) Clean all external dirt and grease from the

pump.

The Pump Housing Must NEVER Be Clamped

in a Vise.

NOTE

A special mounting fixture

must be made to adequately

housing.

(see table 2-2)

secure the pump

(2) Clamp the mounting fixture in a suitable vise.

(3) Install the pump into the mounting fixture,

with two 0.3125’’ -18 UNC-HEX head screws.

(4) Release lock tabs (2) and remove the two control unit retaining plate screws (1) and tab washers

(2, figure 7-34) and the control unit retaining plate

and stop assembly (3). Care fully pull the control unit

assembly (4) with plunger sleeve pin (5) out of the

pump housing (6). Plunger sleeve pin occasionally may

have to be removed separately. Use needle nose pliers

or magnetic pencil.

(5) Remove the delivery valve cap nut (7) and

gasket (8).

(6) Remove the delivery valve holder (9) then

lift out the delivery valve spring (10), delivery valve

assembly (11) and delivery valve spacer (12).
Figure 7-33A

TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Change 6 7-31
TM5-6115-585-34

NAVFACP-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-34

Figure 7-34. Disassembly of fuel Injection Pump (Sheet 1 of 2)

7-32
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

1. Retaining plate screw (2) 14. Copper gasket 27. Spring ring

2. Tab washer (2) 15. Head retaining screws (4) 28. Face gear

3. Control unit retaining plate 16. Head retaining clamps (4) 29. Thrust washer

and stop assembly 17. Head assembly 30. Plunger drive pin

4. Control unit assembly 18. Head"O" ring 31. Timing screw

5. Plunger sleeve pin 19. Head “O” ring 32. Gasket

6. Pump housing 20. Tappet

7. Cap nut

33. “O” ring

21. “O” ring 34. Plunger sleeve

8. Gasket 22. Button spring ring 35. Plunger

9. Delivery valve holder 23. Plunger button 36. Control unit bore

10. Valve spring 24. Lower spring seat washer 37. Pin

11. Delivery valve assembly 25. Seat 38. Flatwasher

12. Valve spacer 26. Plunger spring 39. Lockwasher

13. Locating screw 40. Nut

TS 6115-585-34/7-34(2)

Figure 7-34. Disassembly of Fuel Injection Pump (Sheet 2 of 2)

(7) Remove the hydraulic head locating screw (13)

and copper gasket (14).

(8) Remove the four head retaining screws (15)

and the four head retaining clamps (16). Carefully

rest tappet on clean surface and using shaft head,

hammer pump body assembly until hydraulic head

assembly separates from body assembly.

(9) Remove the “O” rings (18 and 19) from the

hydraulic head and the pump housing.

(10) Remove the tappet (20) and related “O” ring

(21) from the face gear bore.

(11) Remove the spring ring (22) and the plunger

button (23) from the end of the plunger (the plunger is

part of hydraulic head assembly).

(12) Invert the hydraulic head assembly and place

it in a suitable arbor press (see figure 7-35).

(13) Position tool TSE 76215 over the lower spring

seat washer (24, figure 7-34) and depress the plunger

spring, then remove the lower seat (25).

(14) Remove lower spring seat washer (24, figure

7-34) and plunger spring (26).

(15) Place the hydraulic head assembly on a

bench. Using two screwdrivers to carefully pry off

the face gear (28), then remove the thrust washer (29).

(16) Do not remove the plunger (35) out of the

hydraulic head.

NOTE

The Plunger, Plunger Sleeve and Hydraulic

Head are mated Parts and must ALWAYS be

kept together.

c. Inspect (see figure 7-34).

(1) Place the delivery valve assembly in test

fixture TSE 76226 and secure in a suitable vise (see

figure 7-36).

Figure 7-35. Removing Lower Spring Seat

7-33
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Figure 7-36. Delivery Valve Test Assembly

(a) Insert the delivery valve spring (1) and the

delivery valve holder (2). Tighten the delivery valve

holder to a torque of 70-75 ft-lbs. Figure 7-36 illustrates the components that are to be assembled to

test fixture TSE 76226 (3).

(b) Attach test fixture TSE 76226 (3) to a manually operated Nozzle Test Stand.

NOTE

Always check to make certain that all external

connections are tight and that the Nozzle Test

Stand is in good order.

(c) Delivery valve opening pressure is 300-600

psi. Delivery valve must hold 275 psi for 30 seconds.

Remove delivery valve assembly from test fixture.

The delivery valve spring (1) must be free of nicks or

wear (flat spots). Always replace nicked or worn

springs.

7-34

LAPPING COMPOUND MUST NOT COME IN

CONTACT WITH THE RELIEF PISTON DURING THE LAPPING OPERATION, AND ALL

LAPPING COMPOUND MUST BE REMOVED

BEFORE INSTALLING THE DELIVERY

VALVE ASSEMBLY INTO THE HYDRAULIC

HEAD.

(d) If the delivery valve assembly is leaky,

the delivery valve seat may be lapped to its corresponding seat in the delivery valve body with a small

quantity of suitable Lapping ‘Compound.

(2) If the plunger button (23, figure 7-34) is

grooved, ridged, scored, or exhibits an uneven wear

pattern, it must be replaced.

(3) Install a thrust washer (29). Replace thrust

washer if damaged.

(4) Replace the plunger drive gear (28) if the

teeth are worn or damaged.
Figure 7-37. Inspecting Tappet

(5) Inspect the tappet (20) for possible wear at

the contact areas. The primary contact areas are the

tappet contact area and the cam contact area (figure

7-37). Replace the tappet if wear indentations exceed

0.002’. The tappet thickness measured between the

plunger button contact surface and the cam contact

area must be 0.207” or larger.

(6) The pump housing (6, figure 7-34) should be

washed in a cleaning solvent. Check all the screw

threads in the housing, damaged threads can be repaired using thread inserts.

(7) Examine the pump housing for cracks or

other damage which will cause oil leakage. Replace

cracked housings.

NOTE

The control unit assembly is serviceable as a

unit only. Each control unit assembly is furnished with a factory fitted plunger sleeve pin.

(8) Holding sleeve of control unit assembly (4),

rotate lever; shaft must turn freely. If a binding

condition exists, wash assembly in a cleaning agent,

and repeat procedure. If binding condition is still

present, control unit assembly must be replaced. Also

check to make certain that weld holding lever to shaft

is intact.

(9) The flat end of plunger sleeve pin (5) must be

checked for clearance in the mating slot of the

plunger sleeve. If the clearance is greater than 0.0015”,

the entire control unit must be replaced.

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

(10) Plunger sleeve pin (5) must fit snug but must

be free to rotate in control unit assembly.

NOTE

New part clearance is 0.0002-0.00081". If

clearance exceeds 0.0015”, replace control

unit assembly.

d. Reassembly (see figure 7-34).

NOTE

Replace all copper and “O" ring gaskets.

(1) After all parts have been thoroughly cleaned

and inspected and after all worn units have been replaced, dip the individual parts in clean fuel oil.

(2) Invert the hydraulic head (17) and place it on

a clean bench so that the head locating slot is forward.

(3) Refer to figure 7-38 and align the plunger

drive pin (1) into the plunger (2) so that the head of

the plunger drive pin is in the line with the distributor slot. Turn the plunger drive pin until its long side

is parallel to the length of the plunger with long end

up.

Figure 7-38. Assembling Hydraulic Head

7-35
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

(4) Apply a thin coat of petroleum jelly to the

thrust washer (29, figure 7-34) and assemble it to the

hub on the face gear (28).

(5) Carefully center spring ring (27) on hydraulic

head assembly.

(6) Position the face gear (28) and thrust washer

(29) over the end of the plunger and align the head of

the plunger sleeve pin with its mating slot located on

the inside of the face gear (28).

Do not use excessive pressure. If

not snap into place easily, remove

check to see that spring ring (27) is

gear will

gear and

centered,

and that plunger drive pin (1, figure 7-38) is

properly aligned.

(7) Press the face gear (28, figure 7-34) onto the

hydraulic head (17). Make certain that the spring ring

(27) snaps into its mating groove in the face gear (28).

Manually operate the plunger up and down. Free

movement of the plunger indicates that the face gear

has been correctly assembled to the hydraulic head.

(8) With head still in an inverted position, raise

plunger (35) to its highest position.

(9) Apply grease to exposed position of plunger

to keep it in its highest position.

(10) Install spring (26) and spring retaining

washer (24), snap spring seat (25) into place on the

plunger head (35).

(11) Install the plunger button (23) onto the end

of the plunger and secure it by snapping the spring

ring (22) into its mating groove in the lower spring

seat (25).

(12) Check to make sure that the button spring

ring (22) fits tightly into its groove in the lower spring

seat (25). Loose spring rings (22) must be replaced.

(13) Apply a thin coat of petroleum jelly to the

tappet “O” ring (21) and install it into its groove on

the tappet (20). Apply thin coat of petroleum jelly to

inside of tappet. Insert the tappet (20) into the face

gear (28).

(14) Apply a thin coat of petroleum jelly to the

hydraulic head “O” rings (18 and 19). Insert “O” ring

into the head bore of the pump housing (6). Install the

“O” ring into its groove on the upper portion of the

hydraulic head. Ensure “O” rings seat properly.

(15) Clamp pump mounting fixture in a vise, install pump housing in fixture, then carefully insert

the hydraulic head into the pump housing so that the

locating slot in the hydraulic head is in line with the

locating screw hole in the pump housing (not seating).

7-36

(16) Install the head locating screw gasket (14)

and the head locating screw (13) into the locating

screw hole in the pump housing (6). Slight repositioning of the hydraulic head maybe necessary to properly

install the head locating screw. DO NOT USE FORCE.

Tighten screw (13) to a torque of 90 to 100 inchpound. Install head retaining clamps (16) and screws

(15). Alternately tighten screws (15) at opposite corners of housing (6) to properly seat the head assembly (17) in the housing. Tighten screws (15) to 13 to

15 ft-lbs. Insert the timing screw (31) and its gasket

(32) into the timing screw hole in the pump housing.

Tighten the timing screw to a torque of 20 to 25 inchpounds.

(17) Install the delivery valve spacer (12), delivery valve assembly (11), delivery valve spring (10)

and delivery valve holder (9), tighten delivery valve

holder to a torque of 70-75 ft-lbs. Install delivery

valve cap nut (7) and gasket (8). Torque nut to 55-60

ft-lbs.

(18) Insert pin (37, figure 7-34) and flatwasher

(38) into lower hole of lever on control unit assembly

(4) and secure with lockwasher (39) and nut (40).

Tighten to 20-25 inch-pounds.

(19) Apply a film of grease, LU 3003, to the control unit “O” ring (33, figure 7-34), then install “O”

ring in groove in control unit assembly. Ensure that

"O" ring is seated. Apply oil to plunger sleeve pin (5)

and insert the plunger sleeve pin (5) into the control

unit assembly (4).

Figure 7-39. Control Unit Assembly
(20) Place pump in horizontal position with control

unit bore (36 ) facing up.

(21 ) Center the plunger sleeve (34) in the control

unit bore (36 ). Position plunger sleeve pin (5) so that

the flats align with the groove in the control sleeve (34)

and the electric pencil mark (dot ) faces the top of the

pump.

(22 ) Insert control unit assembly (4) into housing

(6), pressing gently until control unit seats.

Do not use force. If flange is not seated on

pump housing, rotate arm both ways with

finger pressure pushing control unit in.

NOTE

Rotate the control unit lever through a 360°

arc to make certain that the control unit assembly is correctly installed. Failure to rotate 360” indicates that the plunger sleeve pin

(5) is not engaging the plunger sleeve slot.

(23) Install control unit assembly retaining plate,

as shown in figure 7-39 using two tab washers and two

screws. Torque screws to 20-25 inch-pounds and bend

locking tabs over screws.

NOTE

If control unit will not seat, pull it out and repeat steps (20) through (22 ).

Figure 7-40. Checking Plunger Sleeve Alignment

TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Figure 7-41. Pressure Testing Injection Pump

e. Test.

(1) Turn pump upside down and depress tappet

with thumb. Tappet should recede 1/16” into face gear

(figure 7-40). If tappet cannot be depressed 1/16” into

face gear, plunger sleeve pin (5, figure 7-34 ) is improperly aligned. Disassembly pump and re-align pin.

(2) Remove the overflow valve assembly from the

fuel outlet hole in the pump housing. Install a 1/4” pipe

plug into the fuel outlet hole.

(3) Secure the pump close to a Nozzle Test Stand.

(4) Cap outlet ports (see figure 7-41 ).

(5) Install C-clamp on injection pumps as shown

in figure 7-41 to retain face gear.

(6) Align holes in face gear and housing (see figure 7-41).

(7) Connect the Nozzle Test Stand to the fuel inlet hole in the pump housing.

Change 4 7-37
TM 5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/04685B-34

NOTE

A fuel inlet stud can be fabricated with a 1/4”

.18 NPT pipe die. High pressure tubing must be

used between the Nozzle Test Stand and the

pump assembly.

NOTE

Always check to make sure that all external

connections are tight and that the Nozzle Test

Stand is in good order.

(8) Slowly operate the Nozzle Test Stand until a

pressure of 400 psi is achieved. A rapid drop in pressure indicates that a leak is present. The pressure must remain

above 250 psi for at least 30 seconds.

DO NOT EXCEED A PRESSURE OF 400 PSI.

(9) Visual inspection should be as follows:

(a) Check for leakage by the head locating screw

(13, figure 7-34).

(b) Slight leakage by control unit shaft

is normal and is necssary to lubricate shaft. Fuel leakage between the control unit body (4)

and pump housing (6) indicates that either thee

o-ring (33) is damaged or the mating surfaces are

damaged. Replace the o-ring (33) and retest the

pump. If fuel leakage is eXCeSSive (Class III,

see TM 5-

6115-585-12, Section 111, Preventative

Maintenance Checks and Services (PMCS) at control

unit shaft or continues past o-ring (33) replace

defective parts.

(c) Check for leakage of fuel around the face gear

(28). If leakage is evident, disassemble pump and inspect

“O” ring (19).

(d) Check for fuel leakage between top of housing

and head flange. To correct, disassemble and replace upper

hydraulic head “O” ring (18).

f. Install (Method 1).

(1) Turn engine flywheel to the port closing mark

(PC) on the front cylinder (closest to blower wheel) compression stroke (see figure 7-44).

(2) Remove timing hole screw located on pump

mounting flange (figure 7-42). Insert a 1/8 inch diameter

wire into the hole.

(3) Rotate pump face gear until wire slips into place

locking the gear in position.

(4) Mount pump on crankcase (see figure 7-32) (be

sure shims (5) are in place) and secure in position using four

hexagon, nuts (2), flatwashers (4) and lockwashers (3). If

“O” ring seal between pump and crankcase is worn, cracked

or otherwise defective, replace it.

(5) Remove wire. Install timing hole screw and

copper gasket.

Figure 7-42. Injection Pump Installation

g. Install (Alternate Method 2).

(1) If pump was not timed by method 1, time now

using alternate method 2 below.

(2) Connect flexible fuel inlet line to pump inlet.

Connect fuel return line.

(3) Connect each fuel outlet line to the proper pump

outlet (see paragraph 7-2).

(4) Connect governor linkage to governor arm.

(5) Start and run engine. Adjust governor linkage if

required (see paragraph 7-3).

A maximum throttle stop screw, located on the

injection pump control assembly, limits the

maximum amount of fuel which can be injected

into the engine. This screw should not be tampered with; it has been properly adjusted at the

factory to protect the engine from over-fueling

(see figure 7-22).

h. Adjust/Time on Equipment.

(1) Time the injection pump to the engine by using

the proper thickness timing button between pump plunger

and tappet (ace figure 7-3 3). Use method 1 when replacing

an old pump if the port closing dimensions and bottom

number of the old pump were recorded. Use method 2 if

the dimensions are lost, and old pump is being timed, or

when replacing either the camshaft or crankshaft:

7-38 Change 5
(2) Timing Method 1. This is a means for calculating the correct button thickness before the pump is

installed. It requires the port closing dimensions and

button thickness from the pump being replaced. Substitute the dimensions for those in the formula below

and calculate the new button thickness. Determine the

button code letter from table 7-1.

Example Formula:

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

NOTE

Always use button thickness closest to this

dimension.

Install the correct button in pump (figure 7-33) and

install pump following the instructions under injection pump installation above.

(3) Timing Method 2. Flowing the Pump.

Port closing dimension of old pump (a) Install a Number 12 or M timing button in

(removed from engine) . . . . . . . . . . 1.093 injection pump and install pump on engine, following

instructions under injection pump installation above.

Button thickness of old pump . . . . . . . +0. 119

1.212

Port closing dimension of new pump . . . . -1.089

When removing tappets which contain timing

Button thickness of new pump . . . . . . . 0.123 buttons, do not allow the portion of the injection pump which has the face gear to be lifted

Use button M from its position.

Figure 7-43. Delivery Valve

7-39
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

Table 7-1. Button Code Letter and Size

Code

No. Or Letter

16

15

14

13

12

1

2

3

4

5

s

R

P

N

M

A

B

c

D

E

Part No.

147A186

147A187

147A188

147A189

147A190

147A147

147A148

147A149

147A150

147A151

Size

0.134

0.131

0.128

0.125

0.122

0.119

0.116

0.113

0.110

0.107

(b) Remove delivery valve cap nut and delivery

valve holder (figure 7-43). A 12 point socket or box

wrench must be used on delivery valve holder to keep

from damaging this part. Lift out delivery valve spring

only, and leave it out, replacing delivery valve holder,

and delivery valve cap nut and gasket.

(c) Turn blower wheel clockwise until Number

1 cylinder (closest to blower wheel) is on compression

stroke, which follows closing of intake valve.

(d) Set throttle lever on injection pump to wide

open or up position (compress stop solenoid plunger

spring or remove stop solenoid assembly). Connect

Number 1 cylinder fuel line to Number 1 pump outlet

so that fuel line projects from the engine, hanging

down. Position receptacle for fuel under the line. Connect lines from fuel supply to transfer pumps, trans -

fer pumps to filter, and filter to injection pump,

operate fuel transfer pumps to obtain fuel pressure

at injection pump. This can be done on the unit by

turning master switch to PRIME & RUN, or just by

applying 24 volts dc across the transfer pump. Rotate blower wheel about one inch counterclockwise so

that P.C. mark is below timing pointer hole.

(e) Rotate blower wheel clockwise until fuel

flows from Number 1 cylinder fuel line. Continue

rotating slowly clockwise until fuel stops flowing. The

point at which fuel stops flowing from Number 1 cylinder fuel delivery line is the injection pump port

closing point. Stop rotation of engine at exactly the

port closing point (l-2 drops in 5-10 seconds).

(f) Check timing pointer in the timing port on

the side of the generator adapter (figure 7-44). If

7-40

Figure 7-44. Timing Port and Port Closing Mark

timing pointer coincides with the P.C. mark stamped

on flywheel, the injection pump button thickness is

correct. If the P.C. mark on flywheel is below the

pointer, injection pump is closing early, and will require a thinner button. If the P.C. mark on flywheel

is above the pointer, injection pump is closing late

and will require a thicker button. Each mark on flywheel indicates a difference of 0.006 inch button

thickness or 2 steps in button code number. (Example:

The P.C. mark on flywheel is above pointer. The

pointer indicates 1-1/ 2 marks difference. A button

0.009 inch thicker or 3 steps difference in button

number code is indicated. Since a Number 12 or M

button is installed, a letter R button is needed. )

(g) Remove injection pump and insert proper

timing button, taking the same precautions not to lift

the assembly containing face gear, when removing

timing button.

(h) Repeat injection pump installation.

(i) Check injection port closing point by repeating steps three through six. The timing pointer

should indicate the P.C. mark on flywheel. In no case

should pointer be more than 1/2 mark away from the

P.C. mark.

(j) Install delivery valve components. Be sure

ll parts are clean, and assembled carefully and
properly. The delivery valve holder must be assembled with a twelve

point wrench, and retorqued to 70-80 ft-lbs dry. The cap nut must be

retroqued to 55-60 ft-lbs dry. On ASK equipped generators, refer to

Operator and Organizational Maintenance Manual and install right

panel and top panel assemblies.

7-19. CYLINDER BLOCK.

(1) Steam clean cylinder block to remove deposits of oil and dirt. Immerse block in solvent tank

to clean out internal passages.

(2) Inspect top surface of cylinder block, the

surface that mates with the cylinder head, for warping.

Check both across cylinders and in line with cylinder.

(3) Use magnetic particle method to check the

cylinder block for cracks. Replace block if cracked.

(4) Cylinder walls should be free of scratches,

pitting and scuffing. Check each cylinder with an

inside reading micrometer for out -of -round and wear.

See Table 1-2 for bore measurements.

b. Overhaul and Rebuild. Always de-glaze cylinder

walls. If necessary, hone or rebore the cylinder to

fit the next available oversize piston. Pistons and

rings are available in 0.005, 0.010, 0.020, 0.030 and

0.040 inch oversize. If cylinders do not need refinishing, remove any existing ridges from top of wall

with a fine stone.

c. Install. If the cylinder block requires replacement a new set of injection pump shims must be used

and the injection pump must be re-timed. The shims

are supplied with the replacement cylinder block. Refer

to paragraph 7-18 a. (3) for calculation of shim

thickness.

7-20. FUEL INJECTOR,

All injector openings and injector nozzles

must be capped when the injector is removed

from the engine.

a. Removal. On ASK equipped generators, refer to Operator and

Organizational Maintenance Manual and remove top panel

assembly.

(1) Remove fuel lines (3 and 7, figure 7-1) at fuel

injectors.

(2) Remove screws (1, figure 7-45), washers (2)

and retaining flanges (3).

(3) Remove fuel injector (4), gasket (5), adapter

(6), gasket (7), heat shield (8) and gasket (9). Separate

injector from other components.

Do not attempt to disassemble nozzles or

adjust nozzle pressure without the proper test

equipment. A nozzle pressure tester is essential to do this work.

TM5-6115-585-34

NAVFAC P-8-623-34

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TM-05684C/05685B-34

Do not allow nozzle to spray against skin. Fuel

under nozzle pressure can penetrate flesh and

cause a serious infection.

b. Test. Install nozzle to be tested on a static fuel

nozzle testing fixture. Increase fuel pressure until

nozzle opens. Opening pressure should be 1950 ± 25

psi for a new nozzle or 1750 ± 25 psi for a used

nozzle (200 hours or more). If nozzle opening pressure is lower, adjust to 1950 psi for a new nozzle or

1750 psi for a used nozzle (see adjustment procedure).

C. Adjust.

(1) Remove pipe plug (1, figure 7-46).

(2) Loosen (do not remove) cover (2).

(3) Install injector nozzle on a static fuel nozzle

testing fixture.

(4) Insert a 5/32 inch hex socket key through hole

in cover (2).

(5) Adjust opening pressure with hex key to correct pressure (1750 Psi for a used injector, 1950 psi

for a ‘new injector). -

(6) Tighten cover

sure.

d. Disassemble.

(2), and recheck opening presNOTE

When removing and disassembling fuel injectors, separate and label components of each

injector. Never interchange components of injectors.

Never clamp injector in a vise without soft

jaws.

(1) Secure injector in a holding fixture and remove nozzle cap nut (12, figure 7-46) and nozzle (9).

NOTE

Do not remove nozzle unless replacement is

required.

(2) Install nozzle cap nut (12) loosely to protect

lapped surfaces of injector body.

e. Clean. Clean injectors in a clean room on a clean

work bench. Provide a pan of clean diesel fuel and a

supply of lint-free wiping cloths. Never use hard or

Change 6 7-41
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NAVFACP-8-623-34

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TM-05684C/05685B-34

Figure 7-45. Injector Nozzle Removal

7-4 2
sharp tools, emery paper, grinding powder, or abrasives of any kind. If necessary, clean outer surfaces

of nozzle body (9) with a brass brush but, do not attempt to scrape carbon from nozzle surfaces, because

severe damage to spray hole can result. Use a soft,

oil soaked cloth to clean nozzle valve. Clean interior

of nozzle cap nut.

f. Inspect. Inspect tappet surfaces of injector body

for nicks or roughening. If damaged, replace injector

body.

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

h. Assemble.

(1) Rinse valve (7, figure 7-46) and nozzle (9)

thoroughly in clean fuel oil before assembly. Valve

must be free in the nozzle. Lift valve (7) about onethird out of nozzle and release; valve should slide

back to seat without aid when assembly is held at 45

degree angle. If necessary, work valve into nozzle

body. Using dry compressed air, blow out fuel inlet

(14).

g. Repair. If cleaning will not eliminate a nozzle (2) Remove all pressure on nozzle spring by

defect, replace nozzle. loosening adjusting screw (3).

1. Pipe plug 7. Valve 12. Nozzle cap nut

2. Cover 8. Valve seat 13. Adapter

3. Pressure adjusting screw 9. Nozzle assembly 14. Fuel inlet

4. Gasket 10. Nozzle gasket 15. Injector body

5. Pressure adjusting spring 11. Cylinder head 16. Gasket

6. Spindle assembly 17. Heat shield

TS 6115-585-34/7-46

Figure 7-46. Fuel Injector

7-43
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NAVFAC P-8-623-34

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TM-05684C/05685B-34

(3) Mount injector in a suitable holding fixture.

(4) Assemble valve (7) and nozzle (9) and install

on body (15).

(5) Install nozzle cap nut (12) loosely.

When tightening nozzle cap nut do not contact

nozzle valve (7).

(6) Place centering sleeve TSE 773 over nozzle

for initial tightening. Remove centering sleeve after

initial tightening to prevent it from binding between

 nozzle and cap nut and tighten nozzle cap nut to 50 to

55 ft-lb dry. -

(7) Adjust opening pressure of nozzle (see paragraph 7-20c).

i. Installation.

(1) Make sure old gasket material has been removed from injector.

(2) Assemble new nozzle gasket (5, figure 7-45),

adapter (6), gasket (7), heat shield (8) and gasket (9)

on injector (4).

(3) Install injector and assembled parts into cylinder head (10).

(4) Install retaining flange (3) and tighten down

with screws (1) and washers (2).”

(5) Reconnect fuel lines as described in paragraph 7-2.

(6) On ASK equipped generators, refer to Operator and

Organizational Maintenance Manual and replace top panel

assembly.

7-44 Change 6

Figure 7-47. Centering Sleeve Installation
TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 8

MAINTENANCE OF GENERATOR ASSEMBLY

Section I. DESCRIPTION AND FUNCTION

8-1. GENERAL.

Refer to Operator and Organizational Maintenance

Manual for description and function of the generator.

Section II. MAINTENANCE

8-2. GENERATOR MAINTENANCE.

a. Test (On Equipment) (see figure 8-1) On generators equipped

with the Acoustic Suppression Kit (ASK), the ASK cover assembly

must be removed for inspection and repair and replaced after completion of task. Refer to Operator and Organizational Maintenance

Manual for removal and installation of ASK cover assembly.

(1) Isolate the trouble to generator or regulator. Disconnect

the voltage regulator at the exciter (wires P67C16 at TB3-5 and

P60E16 at TB3-6). Connect a 12 volt battery in place of the

regulator with the (+) terminal to TB3-6 and (-) terminal to TB3-5.

Run the engine with the battery in place of the voltage regulator. If

there is output now, the voltage regulator is bad. If there is no

output, the main alternator is bad.

(2) Check generator operation. Run the set without

an external load, if the engine appears to be loaded

(dark smoke apparent) the generator may have a winding short to ground. If the engine does not seem to be

loaded, there may be open windings.

(3) Testing Diodes (see figure 8-1). A shorted or

open diode in the rotating rectifier assembly can

cause bad generator operation. This is evident by

failure of the generator terminal voltage to build up

to rated value or a terminal voltage that is too low.

When these symptoms are noticed, and the more obvious sources of trouble, (1) and (2) above have been

eliminated, check the individual diodes of the rotating

rectifier assembly as follows:

(a) Loosen four screws (5) and rotate bell

cover (7) until it can be removed over screw heads.

(b) Disconnect each diode (42) by removing

nuts and washers (40 and 41).

(c) Use an ohmmeter to measure the resistance between the terminal end and the threaded base

(heat sink) end of the diode. Reverse ohmmeter leads

and repeat the resistance measurement. A diode in

good condition will have a very high resistance for

one measurement and a resistance near zero when

ohmmeter probes are reversed. Failure to obtain

these two extremes in resistance measurement indicates a defective diode that should be removed and

replaced.

NOTE

Be sure points of ohmmeter probes are sufficiently long and sharp to penetrate any insulating varnish on diode terminals.

(4) Replacing Diodes. Diodes of the rotating rectifier assembly which are found to be defective or in

questionable condition can be removed and replaced as

follows:

(a) Unsolder wires from diodes.

(b) Install new diode and attaching hardware.

Tighten nut (40, figure 8-1) only finger tight.

(c) Using a 25 to 40 watt soldering iron, solder

leadwires to terminal of replaced diode. To protect

diode from damage due to heat caused by soldering,

hold diode terminal with needle nose pliers as a heat

sink and use a low melting point solder.

(d) Allow each diode to cool after soldering.

Tighten diode mounting nut (40) to torque of 30 inchpounds.

(e) Install end bell cover (7).

(f) Tighten bolts (5).

(5) Resistance. Use resistance check to locate

open circuits.

b. Removal. Refer to paragraph 2-10 for generator

removal.

Change 6 8-1
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TM-05684C/05685B-34

Figure 8-1. Generator Exploded View (Sheet 1 of 2)

8-2 Change 2
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NAVFAC P-8-623-34

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TM-05684C/05685B-34

1. Screw (2)

2. Nut (2)

3. Lockwasher (2)

4. Screen

5. Screw (4)

6. Lockwasher (4)

7. Cover

8. Screw (4)

9. Lockwasher (4)

10. Screw (8)

11. Lockwasher (8)

12. Packing

13. End bell assembly

14. Screw (4)

15. Lockwasher (4)

16. End bell

17. Stator assembly

18. Nut (2)

19. Screw (2)

20. Terminal board

21. Screw (8)

22. Lock plate (4)

23. Pressure plate (4)

24. Screw (8)

25. Lock plate

26. Ring

27. Disk

28. Fan

29. Screw

29A. Screw (MEP-112A)

30. Lockwasher

30A. Lockwasher

(MEP-112A)

31. Flatwasher

31A. Retainer washer

(MEP-112A)

32. Ball bearing

32A. Ball bearing

(MEP-112A)

32B. Washer, Bellville

(MEP-112A)

33. Retainer

33A. Retainer

(MEP-112A)

34. Collar

35. Screw (2)

36. Nut (2)

37. Flatwasher

38. Key

39. Rotor assembly

40. Nut

41. Lockwasher

42. Diode

43. Diode

44. Screw (4)

45. Nut (4)

46. Flatwasher (4)

47. Bushing (4)

49. Heat sink

50. Grommet (2)

51. Insulator (4)

52. Rotor (MEP-003A)

52A. Rotor (MEP-112A)

52B. Screw (MEP-112A)

52C. Lockwasher

(MEP-112A)

52D. Flatwasher

(MEP-112A)

52E. Balance weight

(MEP-112A)

52F. Nut (MEP-112A)

53. Stator assembly

48. Heat sink TS 6115-585-34/8-1(2)

Figure 8-1. Generator Exploded View (Sheet 2 of 2)

c. Disassembly (see figure 8-1).

(1) Remove screws (l), nut (2), lockwasher (3),

attaching screen (4) to generator and remove screen.

(2) Remove screws (5), lockwashers (6), attaching

end bell cover (7) to end bell and remove cover.

(3) Remove screws (8) and lockwasher (9), and

remove end bell assembly.

(4) Remove “O” ring (12) from bearing housing.

Remove and tag wiring harness from terminal board

(20). Remove screws (19) and nuts (18) attaching terminal board to exciter stator and remove terminal

board.

(5) Remove four screws (14) and lockwasher (15)

attaching exciter stator (17) to end bell (16) and remove exciter stator.

(6) Remove eight screws (24) attaching coupling

disk (27) to rotor shaft and remove coupling, lock

plate (25) and retaining ring (26).

(7) Remove generator fan (28) which is now free.

Do not remove balance screw from fan (28).

(8) Remove rotor assembly from stator assembly

(53).

(9) For MEP-003A, remove screw (29), lockwasher (30) and flatwasher (31) attaching bearing (32)

to rotor shaft and remove bearing, bearing retainer

(33) and shaft collar (34). For MEP-112A, remove

screw (29), lockwasher (30), retainer washer (31A)

and Belleville washer (32A), attaching bearing (32)

to rotor shaft and remove bearing retainer (33) and

shaft collar (34).

(10) If necessary, remove diodes from rotor as

given in paragraph 8-2a above.

Do not remove exciter rotor from rotor shaft.

Do not remove balance weight (52E) from

rotor.

d. Inspect. Visually inspect windings and lead connections. Check that diodes are securely mounted on

heat sinks. Clean dust, dirt, and grease from diodes.

Clean windings and drain holes. Check that end bearing is not damaged or worn. Inspect cooling fan and

coupling for damage.

e. Testing Exciter Stator (Field) (High Potential

Test).

Observe safety regulations. The voltages used

in this test are dangerous to human life. Contact with the leads or the windings under test

may cause severe, and possibly fatal, shock.

Arrange the high voltage leads so that they are

not in a position to be accidentally touched.

Keep clear of all energized parts. Always reduce the test voltage to zero and ground the

winding under test before making any mechanical or electrical adjustments on the equipment. When grounding out windings which have

been tested, always connect the connection

wire to ground first, and then to the winding.

Never perform this test without at least one

other person assisting. Generator frame shall

be securely grounded.

(1) General. The high potential test is performed

to determine whether or not the insulation of the

equipment under test is defective. It is customary to

determine whether electrical equipment will withstand

normal voltage stresses by means of a test in which

higher voltages than normal are applied -for a definite

Change 2 8-3
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NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

period of time. The applied voltage must not be so

high as to injure the insulation unless the insulation

was initially defective.

(2) Apparatus. Use acceptable high potential test

apparatus, following the operating instructions of the

manufacturer.

(3) Procedure.

(a) Adequately ground high potential apparatus

to a water pipe or similar electrical ground in accordance with instructions accompanying the apparatus.

(b) Disconnect or remove rectifiers and semiconductors from the circuit prior to conducting the

tests.

(c) Isolate the rotor windings, the main stator

windings, and the exciter stator windings. This is

accomplished by disconnecting the various windings

from any associated control circuits or other connections.

(d) Connect the high-voltage lead from the test

apparatus to the winding or circuit under test. When

testing stator rotor, all windings and circuits must be

securely connected to ground. When testing rotor, all

stator windings and circuits must be connected to

ground.

(4) Test.

(a) Turn on test apparatus in accordance with

manufacturer’s instructions, after making sure that

the initially applied voltage will be not greater than

600 volts.

(b) The test voltage then shall be raised uniformly to the required maximum. This increase shall

be accomplished in not less than 10 seconds nor more

than 30 seconds. The maximum test voltage for rotor

windings shall be equal to 1,000 volts plus twice the

highest rated voltage of the generator. The test voltage for stator windings shall be equal to 10 times for

exciter ceiling voltage but in no case less than 1,500

volts nor more than 3,500 volts.

(c) Apply the maximum voltage for 1 minute.

(d) After 1 minute of applied maximum voltage,

the voltage then shall be reduced gradually to the

voltage initially applied. This reduction shall not be

accomplished in less than 5 seconds.

(e) Turn off test apparatus. Ground the highvoltage lead of the test apparatus to make sure that no

charge remains on the windings which have been under

test.

(f) Remove the high-voltage lead from the

winding and proceed with the tests of the remaining

circuits to be tested. Make sure that all circuits not

under test are securely grounded.

8-4 Change 2

(5) Results,

down is cause

under test.

Any evidence of insulation breakfor replacement of the equipment

f. Winding Resistance Test. Perform winding resistance test using a Wheatstone bridge. Follow the

manufacturer’s instructions given on the bridge. Resistance reading should be 36 ohms ±3.6ohms. Check

resistance between each lead and frame. A low resistance shows that the stator is shorted.

g. Testing Exciter Rotor. Perform winding resistance test and high potential test per MIL-STD - 705A,

methods 401.1 and 302.1. Test between T1

- T2, T2-

T3

, T1T3. See figure 6-2 for location of test points.

Resistance for each winding should be 0.6’77 ohms ±

0.067 ohms. Also test for shorts between windings

and between each winding and rotor core.

h. Testing Generator Stator.

(1) High Potential Test. Test generator stator as

given in paragraph 8-2e of this manual. Replace

stator having faulty insulation.

(2) Winding Resistance Test. Perform winding resistance test using a Kelvin bridge. Follow the manufacturer’s instructions given on the bridge. Resistance readings should be made on the pins of P9 and

P10 (see figure 8-3). Resistance between lead pairs

T 1

- T4, T2- T5, T3- T6, T7- T1 0, T8- T1l and T9- T1 2

should be 0.115 ± 0.112 ohms at 77° F (25” C) for the

MEP-003A. For the MEP-l12A, resistance should

be 0.071 ± 0.007 ohms. Refer to the table in figure

8-3 for location of the terminals.

Also check resistance between each pin A through F

of P9 and P10 and the stator frame. Low resistance

indicates a shorted stator.

i. Testing Generator Rotor.

(1) High Potential Test. Test generator rotor as

given in paragraph 8-2e of this manual. Replace rotor

having faulty insulation.

(2) Winding Resistance Test. Perform winding

resistance test using a Wheatstone bridge. Follow the

manufacturer’s instructions given on the bridge. Resistance reading should

for the MEP-003A and

MEP-112A.

Check resistance between

resistance indicates that

be 3.31 ohms ± 0.33 ohms

3.05 ± 0.305 ohms for the

each lead and frame. A low

the rotor is shorted, a high

resistance indicates open winding.
j.

sink

TM5-6115-585-34

NAVFAC P-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

Reassembly. (2A) For MEP-112A, assemble shaft collar (34),

(1) Install diodes (42and43, figure 8-l) on heat

bearing retainer (33A), washers (32B), bearing (32A),

to the generator shaft using screw (29A), lockwasher

and secure with lockwashers (41) and nuts (40). (30A) and flatwasher (31A).

(2) For MEP-003, assemble shaft collar (34),

bearing retainer (33), bearing (32) to the generator

(3) Place rotor assembly into stator (53).

shaft using screw (29), lockwasher (30) and flat- (4) Position fan (28) in housing (53).

washer (31).

Figure 8-2. Testing Exciter Rotor

Change 2 8-5
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C/05685B-34

(5) Mount coupling disc and fan assembly to the

rotor assembly (52, MEP-113A, or 52A, MEP-112A)

using screw (24) lock plate (25) and retaining ring

(26). Bend lock tabs flat against head of screw (24).

(6) Mount exciter stator (17) to end bell (16)

using screws (14) and lockwashers (15).

(7) Place “O” ring (12) into end bell bearing

housing, attach terminal board (20) to the exciter

stator using screws (19) and nuts (18). Connect previously tagged and removed harness wire terminals.

(8) Mount end bell assembly (13) to the stator

assembly (53) using screw (10) and lockwashers (11).

(9) Install bearing retainer (33, MEP-003A, or

33A, ME-112A) and secure to end bell (16) with lockwasher (9) and screw (8).

(10) Mount end bell cover (7) using screws (5)

and lockwashers (6).

(11) Mount screen (4) to generator, secure with

screw (l), nut (2) and lockwasher (3).

k. Test After Assembly. Rotate the generator

rotor shaft to be certain it rotates freely, that bearings are smooth and rotor does not rub against stator.

1. Installation. Refer to paragraph 2-10 for mounting

of the generator.

m. Generator Winding Data.

(1) Generator frame assembly (see figure 8-3).

(2) Generator rotor (see figure 8-5).

(3) Exciter rotor assembly (see figure 8-4).

8-6 Change 2
Figure 8-3.

TM5-6115-685-34

NAVFACP-8-623-34

TO-35C2-8-455-2

TM-05684C/05685B-34

Change 2 8-7/(8-8blank )
Figure 8-3.1.

TM5-6115-585-3 4

NAVFACP-8-623-34

TO-35C2-3-455- 2

TM-05684C/05685B-34

Change 2 8-8.1/(8-8.2blank)
TM5-6115-585-3 4

NAVFACP-8-262-12

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TM-05684C-34

Figure 8-4.Exciter Rotor Assembly Winding Data

8-9/(8-10 blank)
TM5-6115-585-34

NAVFACP-8-623-3 4

TO-35C2-3-455- 2

TM-05684C/05685B-34

Figure 8-5. Generator Rotor Winding Data (MEP-003A)

Change 2 8-11/(8-12blank )
TM5-6115-585-34

NAVFACP-8-623-34

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TM-05684C/05685B-34

Figure 8-5.1.Generator Rotor Winding Data (MEP-112A)

Change 2 8-12.1/(8-12.2blank)

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TM-05684C/05685B-34

CHAPTER 9

GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL

Section I. GENERAL REQUIREMENTS

GENERAL INFORMATION, tests and inspections specified herein. Activities performing maintenance on any portion of the Generator

Set must perform those tests and inspections required

activity performing the repair or overhaul is by the applicable component or system repair in9-1.

The

responsible for the performance of all applicable struction.

Section IL INSPECTION

9-2. GENERAL.

Inspect entire unit for loose, missing, or damaged parts. Check that

each part is properly painted and protected against corrosive climate

conditions. Check that all parts are properly stowed on unit when not

in use. On ASK equipped generators, cover must be removed for

inspection and replaced at completion of task. Refer to Operator and

Organizational Maintenance Manual for removal and installation of

ASK cover assembly.

9-3. ENGINE COOLING SYSTEM<

Check that all cooling system parts are in place.

Check that there is sufficient clearance between engine

fan and blower housing and grille to prevent rubbing

or binding. Check that shutter assembly operates

freely, without binding.

9-4. WIRING HARNESSES.

Inspect to see that all wiring harnesses are properly

connected and that all connectors are tight. Check that

all wires are secured away from moving parts which

might damage wires.

Section III. OPERATIONAL TESTS

9-5. GENERATOR AND GENERATOR CONTROL CIRCUITRY.

Test per table 9-1.

NOTE

Resistor R3 (20, figure 6-10) in the output

control box, must be adjusted as follows before performing any tests:

a. Remove wire D26F16 from TB3-1 and connect

to 1 amp ac test ammeter as shown in figure 9-1.

b. Place output control switch in 120 position.

c. With the generator operating at rated frequency

the generator field can be flashed by placing the

master switch on the control box in the start position.

d. Close the

load.

e. Adjust R3

reads 0.6 amps.

justed properly.

circuit interrupter and apply rated

until ammeter previously installed

Tighten locknut on R3. R3 is now adf. Disconnect test equipment and proceed with testing in accordance with test schedule table 9-1.

9-6. ENGINE CONTROL CIRCUITRY

a. Test Equipment.

(1) Batteries, 24 volts lead acid (BT1 and 2).

(2) Switch, SPST S1, S2).

(3) Lamps, 24V (Ll, L2, L3, L4, L5, L6, L7).

b. Test Setup. Connect control box and test equipment as shown in figure 9-2.

Change 6 9 - 1
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NAVFACP-8-623-34

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Table 9-1. Test Schedule

Test

Instrument

c. Test Procedure.

Test Method (MIL-STD-705)

513. 1C

Record only the readings of the master

and panel instruments at no-load, 50’%

and 100% of rated load. Record the

readings of the master and panel instruments at all voltage connections.

(1) Position switches as follows:

(a) Master switch-stop.

(b) Panel light switch-off.

(c) S1-closed.

Requirements

Accuracy shall be as follows:

Current indicator system, 10% max.

Voltage indicator system - Initial

accuracy 2. 5% of full scale except that

within the ranges of 115 to 125 and 200

to 250V. The error shall not exceed 3

and 5 volts respectively.

Frequency indicator system 0.5%

maximum.

Voltage adjust range shall be between

197.6 and 218. 4V for the 120/208V, 3

phase 4 wire connection between 114

and 125V for the 120V, 1 phase, 2 wire

connection between 228 and 252V for

the 120/240V, 1 phase, 3 wire connection.

Figure 9-1. Adjusting R3 Resistor Figure 9-2. Testing Engine Control Circuitry

9-2
(d) S2-open.

(2) Place master switch in preheat position.

Lamps L2 and L3 shall light indicating that the preheat circuitry is correct.

(3) Place master switch in start position. Lamps

L1, L2, L3, L4, L5 and L6 shall light indicating that

all circuits for starting are correct.

(4) With the master switch in the start position,

open switch S1, lamp L1 shall extinguish indicating

that the start disconnect circuitry is correct.

(5) With the master switch in the start position,

close switch S2 and then place the master switch in

the prime and run position. Lamps L2 and L3 shall

extinguish lamps L4, L5 and L6 shall remain lit indicating that the prime and run circuitry are correct.

(6) With the master switch in the prime and run

position and lamps L4, L5 and L6 lit, open switch S2.

Lamp L4 shall extinguish indicating that the engine

protective devices circuit and the prime circuit is

correct.

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

(7) Repeat the procedure of step 5, except that

the master switch shall be placed in the prime and

run aux. fuel position after closing s-witch S2. Lamps

L4, L5, L6, and L7 shall remain lit indicating that

the prime and run aux. fuel circuitry is correct.

(8) With the master switch in the prime and run

aux. fuel position and lamps L4, L5, L6 and L7 lit open

switch S2. Lamp L4 shall extinguish indicating that

the engine protective devices circuit and the prime

circuit is correct.

(9) Place master switch in the stop position, all

lamps shall be out indicating that all stop circuits are

correct.

(10) Place panel light switch in the on position,

panel lights shall be on indicating that the panel light

circuit is correct.

(11) Reposition all switches as in step 1 and disconnect test setup.

9-3/(9-4 blank)

TM 5-6115-585-34

NAVFAC P–8-623-34

TO 35C2-3-455-2

TM-05684C/05685B-34

CHAPTER 10

MATERIEL USED IN CONJUNCTION WITH DOD STANDARD GENERATOR

SET ,

10-1.

10KW DIESEL ENGINE DRIVEN, MODELS MEP-003A

Section I. AUXILIARY EQUIPMENT

GENERAL .

AND MEP-112A

This chapter describes all Direct Support procedures for auxilliary equipment (kits) which are used in conjunction with the

generator set. Any effects of the auxiliary equipment on the

maintenance procedures for the generator set are identified in

the maintenance procedures where they occur.

Change 6 10-1
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

SECTION II. ACOUSTIC SUPPRESSION KIT INSTALLATION

10-2. ACOUSTIC SUPPRESSION KIT.

The 10K Acoustic Suppression Kit (ASK) is installed on generator

sets in either the skid or trailer configuration. For the

trailer mounted configuration, the ASK is installed on the

trailer at the approximate location shown in figure 10-1. Table

.0-1 lists ASK parts and related hardware. All required mounting

hardware is supplied with the modification kit. Locate ASK

assemblies, drill mounting holes and assemble as described in the

following paragraphs.

Table 10-1. Acoustic Suppression Kit Parts and

Required Hardware

Item Assembly Related Hardware Qty

1. Right Support

(1, fig. 10-2)

2. Left Support

(5, fig. 10-3)

Rear Panel

(14, fig. 10-2)

3.

4. Rear Flap

(19, fig. 10-2)

5. Rear Closure

(1, fig. 10-4)

6. Side Closure

3/8"-l6xl-1/4LG

Hex Cap Screw

3/8” Washer

3/8” Nut

3/8” Lockwasher

3/8” Bevel Washer

Adhesive Backed Teflon

Use existing Hardware

Adhesive Backed Teflon

l/4"-20x3/4LG

Hex Cap Screw

1/4” Washer

1/4” Locknut

Adhesive Backed Teflon

l/4-20x3/4LG

Hex Cap Screw

1/4” Washer

1/4” Locknut

l/4"-20x3/4LG

Hex Cap Screw

1/4” Washer

1/4” Locknut

Adhesive Backed Teflon

l/4"-20x3/4LG

2

2

2

2

2

Tape 61 in.

4

Tape 61 in.

4

8

4

Tape 11 3/4 in.

3

6

3

4

8

4

Tape 23 in.

14 in.

(4, fig. 10-6) Hex Cap Screw 2

1/4” Washer 4

1/4” Locknut 2

Adhesive Backed Teflon Tape 20 1/2 in.

29 1/4 in.

10-2 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

Table 10-1. Acoustic Suppression Kit Parts and

Required Hardware (Cent)

Item Assembly Related Hardware Qty

7.

8.

Exhaust Plenum

(W/hose & hose clamp)

(13, fig. 10-4)

Left Panel (Short

Side) (2, fig. 10-6)

45° elbow 1-1/4”

l/4"-20x3/4LG Hex Cap Screw

1/4” Washer

1/4” Locknut

Battery Terminal Covers

Adhesive Backed Teflon Tape

a. Attaches to Left

Support Assembly

b. Attaches to Side

Closure Assembly

9. Right Panel (Long

Side) (1, fig. 10-5)

a. Attaches

To Right Support

Assembly

b. Attaches

To Rear

Closure Assembly

c. Attaches

Rear Panel

10. Front Panel

(20, fig. 10-6)

11. Top Panel

(24, fig. 10-6)

a. To Side and

Rear Closure

Assemblies

b. To Left, Right,

and Front Panel

Assemblies

l/4"-20x3/4LG

Hex Cap Screw

1/4” Washer

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

1/4” Washer

1/4"-20 Locknut

l/4"-20x3/4LG Screw,

Hex Cap

1/4” Washer

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

1/4” Washer

1/4"-20 Locknut

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

1/4” Washer

1/4” Locknut

5/16” Shoulder Screw

with 1/4 20 thread

5/16” Washer

Change 6

2

4

8

4

4

1

4

4

3

3

3

3

6

6

2

2

2

2

2

2

6

6

7

7

7

7

13

13

10- 3
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

Figure 10-1. Relocation of Trailer Items to

Accommodate ASK Installation

10-4 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B-34

10-3. PRELIMINARY PROCEDURES.

Prior to ASK installation, perform the following procedures:

a. Refer to Operator and Organizational Maintenance

Manual,paragraph 4-17, and remove the grille (30) from the

engine blower housinq. Store qrille and attaching hardware at

owning units facility.

b. When ASK installation is

mounted generator sets, ensure that

netted to trailer ground.

c. Measure distance between

to be performed on trailer

generator set ground is conskid and tool box. Distance

must be 10 inches minimum. (See figure 10-1.) If distance is

within specification commence ASK installation. If distance is

not within specification perform the following procedures:

(1) Remove hardware securing tool box mounting

brackets.

(2) Relocate tool

inch minimum distance between

(3) Mark mounting

brackets as template.

box to a position that provides 10

tool box and skid.

holes using

(4) Drill new holes at marked

(5) Remount tool box mounting

using existing hardware.

tool box mounting

locations.

brackets and securing

10-4. ACOUSTIC SUPPRESSION KIT INSTALLATION.

a. Right Support Assembly.

(1) Refer to Operator and Organizational Maintenance

Manual paragraph 3-24 and remove engine lifting bracket, shroud

and blower housing.

(2) Refer to figure 10-2 and locate right support

assembly (1) on skid (2) . Align slots (3) in support assembly

(1) with existing screw heads (4) and using support assembly (1)

as template, mark the two additional mounting holes (5) .

(3) Drill two 7/16 inch holes (5) into skid (2) for

right support assembly (1) .

Change 6 10-5
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B-34

Figure 10-2. Installation of Right Support Assembly, Rear Panel

Assembly, and Rear Flap Assembly

10-6 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

(4) Cut a 61 in. length of adhesive backed teflon

tape (as listed in Table 10-1, item 1). Apply adhesive backed

teflon tape to a clean right support assembly top surface

(surface that mounts against underside of skid frame). Use hand

pressure to remove air bubbles. Clear teflon tape away from

screw slots.

(5) Loosen four existing screws (4) and slide right

support assembly (1) between skid (2) and bevel washers (6), as

shown in figure 10-1, detail A.

(6) Install two each screws (7), washers (8), bevel

washers (9), lockwashers (10) and nuts (11) (as listed in Table

10-1, item 1) in the two additional mounting holes (5).

(7) Torque four existing screws (4) and the two added

screws (7) to 26 ±2 ft-lbs dry.

(8) Refer to Operator and Organizational Maintenance

Manual, paragraph 3-24 and reinstall engine lifting bracket,

shroud and blower housing.

b. Left Support Assembly.

(1) Refer to figure 10-3 to remove four screws (1)

and lockwashers (2) securing access plate (3) to AC output

control box assembly (4).

(2) Cut a 61 in. length of adhesive backed teflon

tape (as listed in Table 10-1, item 2). Apply adhesive backed

teflon tape to a clean left support assembly (5) top surface

(surface that mounts against underside of support frame). Use

hand pressure to remove air bubbles. Clear teflon tape away from

screw slots.

(3) Loosen four existing screws (6) and slide left

support assembly (5) between skid (7) and bevel washers (8) as

shown in figure 10-3, detail A.

(4) Torque four existing screws (6) to 26 ±2 ft-lbs

dry.

(5) Refer to figure 10-3 to install four screws (1)

and lockwashers (2) which secure access plate (3) to AC output

control box assembly (4).

c. Rear Panel Assembly.

Change 6 10-7
TM 5–6115-585-34

NAVFAC P-8–623-34

TO 35C2-3–455-2

TM–05684C/05685B–34

Figure 10-3. Installation of Left Support Assembly

10-8 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

CAUTION

When drilling holes, care must be taken not

to damage fuel lines.

(1) Refer to figure 10-2, detail B and drill one 5/16

inch guide hole (12) in generator set control cubicle support

frame (13) at location shown.

(2) Using rear panel assembly (14) as template, align

drilled guide hole (12) with bottom left rear panel assembly hole

and mark location of three remaining holes in generator set control cubicle support frame (13). Drill three 5/16 inch holes.

(3) Cut a 11 3/4 in. length of adhesive backed teflon

tape (as listed in Table 10-1, item 3). Apply adhesive backed

teflon tape to a clean right side surface of rear panel assembly

(14) (surface with 2 captive nuts). Use hand pressure to remove

air bubbles. Clear tape from captive nut openings.

(4) Refer to figure 10-2 to install rear panel assembly (14) to generator set control cubicle support frame (13)

with four screws (15) , eight washers (16 and 17) and four

locknuts (18) (listed in table 10-1, item 3) .

(5) Torque screws (15) to 16 ±2 ft-lbs dry.

d. Rear Flap Assembly.

(1) Refer to figure 10-2 and using rear flap assembly

(19) as template, center assembly on skid, resting rear flap assembly angle on top of skid (2). Mark mounting hole locations

and drill three 5/16 inch holes (20) into skid (2).

(2) Install “rear flap assembly (19) to skid (2) with

three screws (21), six washers (22 and 23) and three locknuts

(24) (listed in table 10-1, item 4).

(3) Torque screws (21) to 16 ±2 ft-lbs dry.

e. Rear Closure Assembly.

(1) Refer to Operator and Organizational Maintenance

Manual paragraph 3-18 and remove air cleaner assembly.

Change 6 10-9
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

CAUTION

When drilling holes, care must be

taken not to damage control

cubicle.

(2) Refer to figure 10-4 and locate rear closure assembly (1) behind mounting brackets (3). Seat clips (3A) of rear

closure assembly (1) over mounting brackets (3), so that rear

closure assembly (1) is positioned over vibration mount hardware.

When positioned correctly, the rear closure assembly (1) is 1/4

inch higher than top of control cubicle (2). Using rear closure

assembly (1) as template, mark and drill four 5/16 inch holes in

mounting brackets (3).

(3) Cut a 23 in. length and a 14 in. length of

adhesive backed teflon tape (as listed in Table 10-1, item 5).

Apply adhesive backed teflon tape to a clean top edge (edge with

three holes) and right edge (edge with two holes which will

contact right panel assembly) of rear closure assembly (1). Use

hand pressure to remove air bubbles. Clear tape from holes.

(4) Install rear closure assembly (1) to control

cubicle support (3) with four screws (5), eight washers (6 and 7)

and four locknuts (8) (as listed in Table 10-1, item 5).

(5) Torque screws (5) to 16 ±2 ft-lbs dry.

(6) Refer to Operator and Organizational Maintenance

Manual, paragraph 3-18, and install air cleaner assembly removed

in step e. (1).

f. Exhaust Plenum Assembly.

(1) Refer to figure 10-4 and install exhaust elbows

(9) (as listed in Table 10-1, item 7) to generator exhaust (10).

Point elbow openings downward (exhaust down).

(2) Install hose (11) over sleeve (12) at bottom of

exhaust plenum (13). Install clamp (14) over hose (11) and

sleeve (12).

(3) Install exhaust plenum assembly (13) over exhaust

shutter assembly (15) until rear upper channel of plenum is flush

with exhaust shutter assembly (15). Screws (15A) in exhaust

shutter assembly (15) fit into plenum slots. (There will be 1-

7/8 inch over-lap.) Using exhaust plenum assembly (13) as

template, mark mounting holes (16) and drill four 5/16 inch holes

in exhaust shutter assembly (15).

10-10 Change 6
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B-34

Figure 10-4. Installation of Rear Closure Assembly and Exhaust

Plenum Assembly

Change 6 10-11
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B–34

shutter assembly (15) with four screws (17), eight washers (18

and 19), and four locknuts (20) (listed in table 10-1, item 7).

(5) Torque screws (17) to 16 ±2 ft-lbs dry.

(6) Route drain hose (11) between batteries and

engine block.

g. Right Panel Assembly (Long Side).

(1) Refer to figure 10-5 and clear out acoustic fill

from holes in right panel assembly (1) using 3/8 inch diameter

pin.

(2) Locate right panel assembly (1) on right support

assembly (2) by aligning captive nuts (3) in right panel assembly

(1) with holes in right support assembly (2). Align captive nuts

(4) in rear panel assembly (5) with holes in right panel assembly

(1) . Align holes in right panel assembly (1) with holes in rear

closure assembly (6).

(3) Install right panel assembly (1) to right support

assembly (2), with five screws (7) and five washers (8). Install

right panel assembly (1) to rear closure assembly (6) with two

screws (9), four washers (10 and 11) and two locknuts (12).

Install right panel assembly (1) to rear panel assembly (5) with

two screws (13) and two washers (14) (as listed in table 10-1,

item 9).

(4) Torque screws (7) and screws (13) to 18 ±2 in.-

lbs dry.

(5) Torque screws (9) to 16 ±2 ft-lbs dry.

h. Side Closure Assembly.

NOTE

Side closure assembly is installed attached

to left panel assembly.

i. Left Panel Assembly (Short Side) with Side Closure

Assembly.

(1) Remove battery connection instruction plate mounted next to batteries by breaking off rivet heads with hammer and

chisel . Clean underside of plate. Refer to figure 10-

6 and reinstall plate (1) on left panel assembly (2) at location

shown with double sided tape (as listed in Table 10-1, item 8).

(2) Refer to Figure 10-6, detail A, and install

battery terminal covers (3). Disconnect cable clamps from

battery terminals. Place 4 each terminal covers (3) over battery

10-12 Change 6
TM 5–6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B–34

Figure 10-5. Installation of Right Panel Assembly

Change 6 10-13
Figure 10-6.

TM5-6115-585-3 4

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B-34

10-1 4 Chang e
TM 5-6115-585-34

NAVFAC P-8-623-34

TO 35C2-3-455-2

TM-05684C/05685B–34

terminals; 2 red terminal covers for positive battery terminals

and 2 black terminal covers for negative battery terminals (as

listed in Table 10-1, item 8). Reconnect cable clamps to battery

terminals. Cover cable clamps with terminal covers (3).

(3) Clear out acoustic fill from holes in left panel

assembly (2) using 3/8 inch diameter pin.

(4) Cut a 20 1/2 in. length and a 29 1/4 in. length

of adhesive backed teflon tape (as listed in Table 10-1, item 6).

Apply adhesive backed teflon tape to a clean top edge (surface

which will mount against top panel assembly) and left edge (edge

with three holes) of side closure assembly (4). Use hand

pressure to remove air bubbles. Clear teflon tape away from

screw holes.

(5) Install left panel assembly (2) to side closure

assembly (4) with three screws (5), six washers (6 and 7) and

three locknuts (8) (as listed in table 10-1, item 8.b).

(6) Torque screws (5) to 16 ±2 ft-lbs dry.

(7) Locate left panel assembly (2) (with side closure

assembly (4) attached) on left support assembly (9) by aligning

captive nuts (10) in panel with holes in left support assembly

(9) . Align side closure assembly mounting holes (11) with rear

closure assembly mounting holes (12).

(8) Install left panel assembly (2) with side closure

assembly (4) to left support assembly (9) with four screws (13)

and four washers (14) and to rear closure assembly (15) with two

screws (16), four washers (17 and 18) and two locknuts (19) (as

listed in table 10-1, item 8.a. and item 6).

(9) Torque screws (13) securing left panel assembly

(2) to left support assembly (9) to 18 ±2 in.-lbs dry.

(10) Torque screws (16) securing side closure assembly

(4) to rear closure assembly (15) to 16 ±2 ft.-lbs dry.

j. Front Panel Assembly

(1) Refer to figure 10-6 and clear out acoustic fill

from holes in front panel assembly (20) using 3/8 inch diameter

pin.

(2) Install front panel assembly (20) to right panel

assembly (21) and left panel assembly (2) with six screws (22)

and six washers (23) (as listed in table 10-1, item 10). Start

all screws by hand first.

(3) Torque screws (22) to 18 ±2 in.-lbs dry.

Change 6 10-15
TM 5-6115-585-34

NAVFAC P-8–623-34

TO 35C2-3-455-2

TM–05684C/05685B–34

k. Top Panel Assembly.

(1) Refer to figure 10-6 and clear out acoustic fill

from holes in top panel assembly (24) using 3/8 inch diameter

pin.

(2) Locate top panel assembly (24) by aligning holes

in top panel assembly (24) with captive nuts in left panel assembly (2), right panel assembly (21) and front panel assembly

(20), and with holes in side closure assembly (4) and rear

closure assembly (15).

(3) Install top panel assembly (24) to left panel

assembly (2), right panel assembly (21) and front panel assembly

(20) with 13 screws (25) and 13 washers (26). Install top panel

assembly (24) to side closure assembly (4) and rear closure assembly (15) with seven screws (27), 14 washers (28 and 29) and

seven-locknuts (30) (as listed in Table 10-1, item 11).

10-5 .

(4) Torque screws (25) to

(5) Torque screws (27) to

POST INSTALLATION PROCEDURES.

The local safety

Medicine Support

prior to initial

WARNING

18 ±2 i n . -lbs dry.

16 ±2 ft-lbs dry.

office and Preventative

Activity must be consulted

CARC painting.

Inspect ASK and generator set for any areas where touch-up

painting may be required. Perform necessary touch-up painting in

accordance with MIL-T-704 using paint colors green 383, brown

383, and black as required in FED-STD-595.

10-16 Change 6
1.

2.

3.

4.

5.

PAINTING:

T.O. 35-1-3

RADIO SUPPRESSION:

MIL-STD-461

MAINTENANCE:

T.O. 00-25-225

T.O. 00-25-235

T.O. 1-1-1

T.O. 1-1-2

T.O. 31-1-75

T.O. 35-1-11

T.O. 35-1-12

T.O. 35-1-26

T.O. 35-1-524

T.O. 34Y19-1-111

AFM 66-1

T.O. 35C2-3-1-426

SHIPMENT AND STORAGE:

T.O. 35-1-4

T.O. 38-1-5

DESTRUCTION OF MATERfAL:

TM 750-244-3

TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

APPENDIX A

REFERENCES

Painting and marking of USAF Aerospace Ground Equipment.

Radio Interference Suppression.

Repair of External Power Cables, Aerospace Ground Equipment.

General Shop Practice Requirements for the Repair, Maintenance and

Test of Electric Equipment.

Cleaning of Aerospace Equipment.

Corrosion Control and Treatment for Aerospace Equipment.

General Maintenance Practices.

Organization, Intermediate and Depot Level Maintenance for FSC 6115

Equipment.

Components and Procedures for Cleaning Aerospace Ground Equipment.

Repair/Replacement Criteria for FSC 6115 Aerospace Ground Equipment.

USAF Equipment Registration Number System Applicable to FSC 6115

Equipment.

Electric Motor and Generator Repair.

AF Maintenance Management.

Inspection and Maintenance of FSC 6115 Electrical Generator Set.

Processing and Inspection of Aerospace Ground Equipment for Storage

and Shipment.

Processing and Inspection of Non-Mounted, Non-Aircraft Gasoline and

Diesel Engines for Storage and Shipment.

Procedures for Destruction of Equipment to Prevent Enemy Use.

A-l/ (A-2 blank)

ALPHABETICAL INDEX

Subject

A

AC Instrumentation stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acoustic Suppression Kit, Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Acoustic Suppression Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts and Hardware Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Post Instalation Procedures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relocation of Trailer Items to Accommodate ASK Installation . . . . . . . . . . . .

AC Output Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Components . . Removal . . . . .

Test Set-Up . . . . . .

Wiring Harness . . . . .

Auxiliary Equipment . . . .

Battery Charging Alternator

Blower Wheel . . . . . . .

Bridge Rectifier Assembly

Testing . . . . . . . .

Camshaft . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B

TM5-6115-585-34

NAVFACP-8-623-34

TO-35C2-3-455-2

TM-05684C/05685B-34

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

c

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph,

Figure, Table,

Camshaft Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centering Sleeve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description and Function.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft and Camshaft Gear Timing Marks . . . . . . . . . . . . . . . . . . . .

Crankshaft End Play Measurement . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Gear Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Pistons and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Blow . . . . . . . . . ............. . . . . . . . . . . . . . . .

Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bolt Tightening Sequence.. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . .

D

DC Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery Valve Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting Engine from Generator . . . . . . . . . . . . . . . . . . . . . . . .

E

Engine Assembly

Description and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number

6-2

1 - 7

10-4,F10-2

thru F10-6

T10-1

10-3,F10-1

10-5

F10-2

6-8

F6-9, F6-10

6 - 9

F6-8

F6-7

6-7, F6-6

T6-3

10-1

7-8, F7-7

7-7, F7-7

F6-11

T6-6

7-16

F7-25

F7-47

F7-17

F7-19

6-4, F6-3

2-8

F6-1, T6-1

F7-39

F3-1

3-1

9-3

3-2

7-17

F7-30

F7-26

F7-31

F7-28

F7-29

F7-15

7-19

7-9, F7-11

F7 -13

F7-9

6-1

F7-36

F2-2

7-1

2-0

Change 6 INDEX 1
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

ALPHABETICAL INDEX (CONT)

Subject

Paragraph,

Figure, Table,

Number

E (CONT)

Engine Control Circuitry Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exciter Rotor

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winding Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Governor and Speed Control . . . . . . . . . . . . . . . . . . . . . . . .

F

Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel and Ring Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injection Pump

Button Code Letter and Size . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tappet Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System, Description and Function . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

 7-5

G

Gear Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator and Control Circuitry Test . . . . . . . . . . . . . . . . . . . . . . . .

Generator Frame Assembly Winding Data . . . . . . . . . . . . . . . . . . . . . .

Generator Rotor WindingData . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test and Inspection after OverhauI . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Cup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H

High Temperature Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I

Injection Pump Adjustment and Button Removal . . . . . . . . . . . . . . . . . . .

Injection Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6, F9-2

F8-2

F8-4

7-3

2-3, T2-2

7-4, F7-3

T7-1

7-18

F7-37

7-20, F7-46

F7-45

7-2

4-1

4-2

7-14, F7-22

F7-23

2-6

F8-1

8-1

8-2

2-10

9-5

F8-3

F8-5

1-6

F1-1

9-1

6-5

F6-2, T6-2

7-15, F7-24

3-3

F7-38

F7-33

F7-32

F7-43

F7-34

F7-42

F7 -41

F7-1

F7-21

INDEX 2
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

ALPHABETICAL INDEX (CONT)

Subject

L

Levels of Maintenance Accomplishment . . . . . . . . . . . . . . . . . . . . . . .

Lifting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Engine - Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . .

Load Terminal Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower Spring Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

s

Paragraph,

Figure, Table,

Number

M

Manual

Limited Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

0

Oil By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13, F7-20

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-6

Oil Filter Adapter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Removal . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-19

P

Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, F7-14

Piston Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-16

Piston Top Dead Center Measurement . . . . . . . . . . . . . . . . . . . . . . . . F7-5

Plunger Sleeve Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-40

R

Reconnection Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . T6 -5

Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Repair Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-2

Reporting of Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Resistively Loading the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . F7-8

Resistor R3 Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1

1-5

2-3

F2-4

T6-4

F7-35

Solenoid Switch, Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Starter Armature

Testing for Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing for Shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Brush Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Brush Spring -Checking Tension . . . . . . . . . . . . . . . . . . . . . .

Starter Commutator

Checking Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Undercutting Mica..... . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Pinion, Checking Clearance . . . . . . . . . . . . . . . . . . . . . . . . .

Starting System

Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F5-2

2-2, T2-1

F2-1, F7-2

F5-3

F5-4

F5-1

F5-9

F5-7

F5-5

F5-8

F5-10

5-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

INDEX 3
TM5-6115-585-34

NAVFAC P-8-262-12

TO-35C2-3-455-2

TM-05684C-34

ALPHABETICAL INDEX (CONT)

Subject

T

Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Port and Port Closing Mark . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V

Valve Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Regulator

Schematic . .

Testing . . .

Wiring Harnesses,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph,

Figure, Table,

Number

1-7

T9-1

F7-27

F7-4, F7-44

T1-1

2-4, T2-3

F7-12

F7-10

6-3, 6-6

F6-5

F6-4

9-4

INDEX 4
TM 5-6115-585-34

NAVFAC P-8-262-12

TO 35C2-3-455-2

TM 05684C-34

By Order of the Secretaries of the Army, the Navy, and the Air Force:

Official:

BERNARD W. ROGERS

General, United States Army

Chief of Staff

PAUL T. SMITH

Major General, United States Army

The Adjutant General

D. G. ISELIN

Rear Admiral, CEC, U. S. Navy

Commander,

Naval Facilities Engineering Command

Official:

JAMES J. SHEPARD, Colonel, USAF

DAVID C. JONES, General, USAF

Chief of Staff

Director of Administration

W. R. JOHNSON

Brigadier General, U. S. Marine Corps

Acting Deputy Chief of Staff for Installations and Logistics

Distribution:

To be distributed in accordance with DA Form 12-25D, Direct/General Support maintenance requirements

for Generator Sets, Engine Driven: 10 KW, 60 HZ.

 U.S .GOVERNMENT PRINTING OFFICE : 1995 O - 387-315 (22384)


PIN: 033750-000